IN 1411 – Reactivation of DP vessels following a period of lay-up

This Information Note was produced under the supervision of the IMCA Marine Division Management Committee (MDMC).

During 2017, the committee recognised that with improving industry metrics, member companies could now be considering reactivating their owned and managed vessels, following a period of layup. This Note has been produced as a product of two workshops and a workgroup drawing on IMCA’s global presence. Members of the workgroup represented vessel operators, consultant companies specialising in DP and system manufacturers.

Guidance covering the reactivation of DP vessels already existed and there was no requirement to duplicate this information. Therefore, this information note provides an aide memoir when preparing for and during the reactivation of DP vessels.

Steps should be taken to ensure it is safe for crew to go onboard.

1.1 Crew considerations

• Define International Maritime Organization (IMO) Safe Manning Document.
• Define operational crew required for the specific vessel, mission and geographic area.
• Define International Convention on Standards of Training, Certification and Watchkeeping for Seafarers (STCW) requirements.
• Compile Matrix for offshore courses, training, health certificates, etc.
• Hire crews and ensure relief crews familiarise themselves with their roles prior to departure.
• Ensure compliance with The Training and Experience of Key DP Personnel (IMCA M 117).
• Base familiarisation and training requirements on Guidance on competence assurance and assessment: Marine Division (IMCA C002).
  
  

1.2 Support staff requirements

• Office support staff for both reactivation and operation:
  – critical vendors with timelines of availability. For example, engine, thruster and DP system original 
  equipment manufacturers (OEMs).

• Allocating budget responsibilities – owners/partners/equipment suppliers.
• Renewal/reinstatement of flag/class/P&I/H&M surveys and audits.
• Spare parts budgets– requirements (reference section three).
• Personnel/crewing budgets – requirements (reference section one).
• Third-party contractors – requirements (reference section three).
• One-time cost for spares and consumables used during initial reactivation work plan (reference section three).
• Replenishing on-going stock levels of vessel consumables for example:
  • Fuel.
  • Lubes.
  • Potable water.
  • Paint & chemicals.
  • Engine room stores.
  • Deck stores.
  • Hotel items (linen, kitchen items, cutlery, crockery, etc).
  • Catering stores.
  • Batteries.
• Logistics:
  • Agency.
  • Berths.
  • Shipyard.
  • Port dues.
  • Travel & transport.
  • Accommodation.
  • Catering.
  • Security.
  • Import/export.
  • Vessel clearance.
• Communications:
  • Re-activation of communications systems.
  • Commissioning and testing.

3.1 Initial planning

• Notify interested parties (flag, class, insurance, Port state etc) and include any vessel reinstatement requirements from these bodies.
• Appoint office planning personnel (technical superintendent, purchasing officer).
• Review planned maintenance system (PMS), vessel specific technical and operations manuals (if applicable) and initial vessel layup/preservation works, and prepare initial work plan and schedule (include annual servicing and survey renewal requirements as well as general maintenance).
• Review spare parts inventory and identify items that may require checking by OEM (e.g. PCBs).
• Identify required parts, lead time and consumables for the above and order (check vessel inventory of spares – work to commence on equipment where there are already spares available, and these should
  be replaced by parts ordered in due course).
• Identify any obsolete equipment requiring renewal or new regulatory requirements (e.g. ballast water and sediments management plan (BWMP)).
• For all equipment, identify any OEM specialists required and include in schedule (e.g. DP, engine and thruster OEM, etc) – OEM should be contacted for any equipment requiring software upgrades, etc.
• Identify any equipment removed from the vessel whilst cold stacked (e.g. portable fire extinguishers) which can be serviced and returned to vessel off critical path.
• Appoint a vessel agent.
• Appoint a shipyard or layby berth as appropriate.
  
  

3.2 Mobilisation to vessel – first steps – shore based personnel and crew based ashore

• Emergency procedures must be issued prior to access to the vessel, including confined space entry and rescue procedures. Contact details for local emergency support such as medical & firefighting should be available and temporary emergency equipment such as fire extinguishers, first aid kits, extraction/evacuation equipment etc., should be provided.
• Assuming the vessel has been cold stacked for some time and locked up, the first step is to ensure internal spaces are checked for presence of fumes and/or lack of oxygen.
• Include the possibility of shore power and cold start.
• Once the vessel is entered, first check on the functionality and availability of fire detection, firefighting and bilge monitoring systems.
• Start the emergency generator (after checks) and start the engine room supply and exhaust fans and the accommodation fans to circulate fresh air.
• Prepare for testing and recertification of safety equipment (e.g. third-party servicing of fire extinguishers and life rafts) if out of date.
• Operate all sea water systems and check for leaks/repairs as necessary.
• Take oil samples from all systems and oil and fuel storage tanks and send for analysis.
• Plan cleaning of all seawater coolers.
• Clean fridge rooms, start refrigeration system and bring rooms to desired temperatures.
• Chemically clean the air conditioning (AC) system evaporator.
• After cleaning the AC system, start the air conditioning systems and bring accommodation to desired temperature.
• Dump all fresh water (FW) on board and clean all FW tanks. After cleaning, fill all potable tanks and dose with chlorine.
• After dosing period, flush through all domestic water pipelines until the water is clear and tests indicate 0.05 – 0.5 ppm free chlorine.
• Conduct domestic water inspection/tests for bacterial infestation, for example Legionnaires disease
• Test hot water hydrophore systems.
• Commission sewage system and accommodation toilets.
• Commence cleaning of cabins and laundry of bed linen, towels and curtains from cabins, to be allocated to first batch of personnel to live on board.
• Mobilise personnel on board.
  
  

3.4 Commencement of maintenance work identified in 3.1 – Personnel living onboard

• Hull:
  • Docking:
    • Inspection for damage.
    • Clean hull of marine growth.
    • Testing of propulsion system and rudders for set up and free movement.
    • Sea chests.
    • Ship side valves.
    • Underwater hull and sea chest anodes.
    • Hull penetrating sensors.
  • Coatings.
• Deck.
• Tanks & void spaces.
• Superstructure.
• Accommodation.
• Hotel services.
• Machinery spaces.
• Systems – full system checks similar to the original commissioning checks when vessel was new, cover all machinery systems and not just the DP systems.
• Engines.
• Compressors and air reservoirs.
• Rudders/propellers/thrusters/tail shafts.
• Anchors and mooring systems.
• Electrical:
  • Generators
    • switchboard (including all system insulation checks).
    • IT systems.
    • communications.
    • control systems.
    • Bridge equipment.
  • Mission equipment (Refer to section seven).
    
    

3.4 Review of failure modes and effects analysis (FMEA) and proving trials documents following maintenance and upgrades

• Early engagement of all equipment OEM to review software/hardware update requirements.

A proving trial plan and schedule covering the reactivation trial period should be developed.

4.1 Purpose of reactivation trials

• Performance and functionality.
• Failure modes, detection and protection.
• Confirming reliability.
• Class requirements.
• Charter requirements.

4.2 Lay-up factors affecting the reactivation trials programme

• Lay-up preparation.
• Lay-up duration.
• Maintenance performed during lay-up.
• Lay-up location and related environmental conditions.
  
  

4.3 Documentation/inspection to develop a trial program (inputs)

• Records of lay-up and reactivation maintenance and appropriate recertification.
• FMEA and trials documentation.
• Recommissioning performed (if performed/needed).
• Modifications (if performed).
  
  

4.4 DP subsystem specific guidelines for reactivation trials 

• Refer to section six.
  
  

4.5 Personnel and responsibilities

• Determine the parties to be involved in the trials (owner, class, flag, client, crew, vendors, independent 
  surveyors, etc.).
• Roles and responsibilities during the trials period to be clearly defined.

4.6 Follow up actions 

• Closeout of findings and recommendations.
• Review of operational documentation.
• Management of change (MoC) should be updated as appropriate.
• Provide feedback and lessons learnt.

5.1 The following should be notified at the earliest opportunity

• Flag and prepare vessel for Flag state audits, including International Safety Management Code (ISM Code).
• Classification society and prepare vessel for class survey.
• P&I for vessel reactivation and return to operation.
• Hull & Machinery Insurance (H&M) and their requirements completed.
• Third-party inspectors for recertification of dive systems, ROV systems, cranes, helidecks, eCMID and OVID inspections, etc.

The list provided is indicative, there may be other vessel specific systems or subsystems that require to be considered on a case by case basis.

6.1 Engines & marine systems

Prime movers with necessary auxiliary systems including but not limited to the following:

• Engine control & monitoring systems.
• Fuel oil systems.
• Cooling systems.
• Lubrication systems.
• Compressed air systems.
• Hydraulic power systems.
• Associated piping and routing.
• Software/firmware.
  
  

6.2 Electrical systems

All components and systems necessary to supply the DP system with power, including, but not limited to:

• Generators including hybrid systems if applicable.
• Switchboards.
• Transformers.
• Active or passive filter systems.
• Power regeneration systems.
• Distribution systems.
• Uninterruptible power supply (UPS) and battery systems.
• Power management systems.
• Associated cabling and cable routing.
• Software/firmware.
  
  

6.3 Propulsion and thrusters

All components and systems necessary to supply the DP system with thrust force and direction, including, but not limited to:

• Thrusters with drive units and necessary auxiliary systems.
• Main propellers and rudders.
• Thruster control systems including feedback linkages and emergency stops.
• Manual/local thruster controls.
• Associated cabling and routing.
• Network systems.
• Software/firmware.

6.4 Vessel Control & Monitoring Systems including DP

All control components and systems, hardware and software necessary to dynamically position the vessel, consisting of:

• Computer system.
• Independent joystick.
• Sensor systems.
• Control stations and display system (operator panels).
• Position reference systems including appropriate transponders.
• Associated cabling and cable routing.
• Networks.
• Vessel monitoring/alarm systems.
• Communication systems including voice and DP alert system.
• Printers and data loggers.
• Software/firmware.

6.5 Mission equipment that could impact the DP control system

• Emergency shutdown systems (ESD).
• Fire and gas systems.
• Equipment that could cause an external force.
• Equipment that could cause a regenerative load.
• Third-party equipment connected to the DP system.
• Gangway walk to work (W2W) system.

This section refers to the equipment that is required for the vessel to conduct its industrial mission. The list is not exhaustive and is included to remind users that each of these systems, if fitted, will require its own plan for reactivation.

7.1 Mission critical equipment to be considered in the reactivation programme

• Deck machinery.
• Heavy lift cranes.
• Subsea cranes.
• Dive systems.
• Pipelay systems.
• ROV systems.
• Survey systems.
• Drilling systems.
• Gangways including W2W systems.
• Jacking system.
• Mooring system.
• Emergency disconnect system.
• Project equipment that needs modification.

8.1 Security

• Safely moored
• Security of vessel
• Security of crew
• Security of third-parties involved in the process
• Damage/pilfering/sabotage.

8.2 Environmental conditions

• Atmospheric conditions including effects on people and equipment.
• Local water conditions – temperature, water type and content.
• Content of ballast tanks.
  
  

8.3 Facilities

• Appropriate berthing and anchorage available.
• Available storage facilities.
• Access to cranage.
• Repair workshop availability.
• Shore power availability.
• Fire, safety and security facilities.
• Local medical facilities.
• Consider relocation for the purposes of reactivation.
• Waste reception facilities.
• Specialised means of access requirements.

8.4 Logistics

• Available expertise and skill sets.
• Ship chandler.
• Logistical reliability.
• Available survey authorities.
• Accommodation and travel logistics.
• Vessel formal inward/outward clearance including local regulation.
• Crew and third-party documentation – work permit & visa.
• Formality clearance included tax for equipment/store/supply to vessel.

• An in-water survey should cover thrusters, propellers, rudders, sea chests, hull openings (transducers, echo sounder, etc.), marine growth, anti-fouling status, anodes, damage, etc.
• Ensure it is safe to enter the vessel. Compartments might be low on Oxygen, trunks and confined spaces, engine room wells, transducer trunks, etc. might contain standing water with Hydrogen Sulfide (H2S). Prepare a plan covering all areas and eventualities ensuring appropriate gas detectors are used.
• Check all ship side valves against the ship’s side valve drawing.
• Check all sea chests and ensure sea chests are clean on the inside.
• Prepare a plan to check all system valves. Use the pipeline and instrumentation drawing plan which will assist the new crew to become familiar with the vessel.
• Check watertight integrity. Check all watertight doors, closures, etc. against ship drawings and operate locally, remotely and automatically as appropriate.
• Prepare a maintenance plan for the in-water part of the vessel, utilising the docking plan, anode plan and sea chests plan.
• Do a stability calculation, using both manual calculation and available software. Reference the stability manual and curves and make the calculation as soon as tank measurements are available.
• Check passive fire protection based on the safety plan or fire protection plan.
• Check fixed firefighting equipment and pay special attention to Carbon Dioxide (Co2) and other gaseous fifi equipment.
• Check all compartments on board based on the general arrangement plan, tank plan, etc.
• Check ballast system.
• Check bilge system.
• Check emergency bilge system.
• Check firewater system and international shore connection.
• Check for rodents, insects, etc.

As the industry continues to reactivate vessels there are many organisations, such as equipment vendors, classification societies, P&I clubs and industry associations, producing guidance to aid the vessel owner. As lessons are learned and the level of reactivation increases the level of guidance will evolve.

However, the following provides a list of existing guidance that could be useful to Members:

• American Bureau of Shipping; Guide for Lay-up and Reactivation of Mobile Offshore Drilling Units; Houston, TX; May 2016.
• Bureau Veritas; Guidance Note NI545 DNS R01 E – Guidance for Lay-Up of Ships; 2018.
• Bureau Veritas; Guidance Note NI 649 DT R00 E Guide for the Lay-up and reactivation of DP vessels; 2018.
• DNV GL; Lay-up of Vessels; March 2012.
• DNV GL; Procedure for the lay-up of Mobile Offshore Units; April 2015.
• Lloyds Register; Ship Layup guidance; October 2015.
• IMCA; Guidance on competence assurance and assessment: Marine Division (IMCA C002).
• IMCA; The training and experience of key DP personnel (IMCA M117).
• IMCA; Guidance for developing and conducting DP annual trials programmes (IMCA M190).
• IMO; Guidelines for vessels with dynamic positioning systems (MSC Circular 645) (113 IMO).
• IMO; Guidelines for vessels and units with dynamic positioning (DP) systems (MSC.1/Circ. 1580) (245 IMO).
• IMO; The International Convention on Standards of Training, Certification, and Watchkeeping for Seafarers (STCW).
• MTS DP Committee; DP Asset Reactivation Guidance.
• West of England P&I Club; Layup vessel Reactivation.