Reducing the cost of conversion projects through design for ship conversion

Abstract

The Thesis develops design and production methods to reduce cost, duration and risks of conversions. It reviews the literature on the nature of conversion and its correlation to ship-repair and shipbuilding. It examines the market, in particular for tanker to bulk carrier conversions. Literature on ship design for production, project management and risk is reviewed to identify potentially valuable ideas to improve the conversion process. The case study conversion was completed in a conversion yard, using conventional techniques and planning. The design of the final bulk carrier was also conventional. The work was completed afloat, creating potential risk of structural damage which required carefully managed actions, e.g. work inside cargo holds to be carried out sequentially. A project completion review identified this and access difficulties as slowing the work. A number of cost inducing conversion bottlenecks had not been obvious at the start. An alternative design is proposed for subsequent projects, moving strength members above deck, minimizing bottlenecks present with the initial design. Indicatively, by providing adequate deck strength early in the conversion, work in the cargo holds could proceed more quickly. A plan for conversion is developed alongside the design. The alternative design shows a significant cost and time saving. The results are developed to offer a general basis for design for conversion, adapting shiprepair and design for production principles and proposes the following: - The need to understand conversions in depth and improve planning. - The need to engage all parties (design and production) in a collaborative project. - Mitigation of risks focusing on production methods. - A dedicated Goal-Based Design for Conversion approach that avoids, where possible, difficult internal structural work. - Evaluating the need for Dry Dock in major conversions; it may not always be necessary or beneficial, contrary to popular belief and current Bibliography.