The document discusses shipbreaking procedures and methods. It describes the technical knowledge and physical labor required to dismantle ships. It explains the two main methods: the afloat method near the water and the dry-dock method out of water. The dry-dock method is easier but more expensive. The document then outlines the typical steps taken in scrapping a ship, including removing hazardous materials and disposing of wastes properly.
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http://www.infomarin.ru/compe/sbreak.shtmlquot;
http://www.infomarin.ru/compe/sbreak.shtml<br />Shipbreaking Procedures<br />The skills required to dismantle a ship are a unique blend of technical knowledge and physical labor. Technical knowledge is needed to properly eliminate hazardous materials and safely remove heavy sections of steel hulls. Ship scrapping is still a labor-intensive process with much of the work being done using hand held cutting tools<br />The two methods of scrapping a ship are the afloat method and the dry-dock method. The afloat method is generally less expensive than the dry-dock method, but this cost savings comes with greater difficulty than the dry-dock method. Scrapping a ship while in the water is more difficult because of the scrappers need to strip the inside of the ship before dismantling can begin. Workers must strip the interior through doors and hatches and remove the propeller(s) and rudders while the ship is in the water. Then, the scrappers remove the superstructure and topside components and progressively cut the main and lower decks from bow to stern. As they remove material from the ship it becomes lighter and is pulled ashore, a little more each day, with each high tide. Scrapping a ship in a dry-dock is more expensive, yet it is easier to scrap the vessel. Since the ship is not in the water, the workers can immediately begin separating the vessel into large sections, then move the large sections to other areas to be cut into smaller sections.<br />After removal from the fleet site, a ship is towed to the site where ship scrapping will occur. The ship is then scrapped while either moored, beached, or in drydock. Most ship scrapping is performed at slips, which are dredged openings in the bank of the ship channel. Slips are generally 400 to 700 feet long and 100 to 120 feet wide at the entrance. A large winch at the head of the slip is used to drag the hull farther into the slip as work progresses. The scrapping process usually occurs in a series of steps:<br />A diagram of all rooms, compartments, tanks, and storage areas is used (or prepared if not available) to identify areas that may contain hazardous materials, such as fuels, oils, asbestos, PCBs, and hazardous waste. Preliminary sampling of media is conducted, starting in the compartment that will be cut first.Other materials that are not recycled, including hazardous materials and other wastes, are disposed of according to applicable laws and regulations.<br />Priya Blue_______________________________________________________ <br />http://www.priyablue.com/<br />Priya Blue Industries Pvt Ltd is one of the established and leading recycling units in Alang/Sosiya (Gujarat, India). Our company is a member of Priya Group of Industries.<br />We have recycled 34 ships out of which 6 are ULCC’s and 5 were VLCC’s ships. We have successfully recycled one of the largest passenger vessel Ex SS France Ex SS Norway “BLUE LADY” that was monitored by the Honorable Supreme Court appointed committees to ensure all statutory procedures with respect to safety, health and the environment are fully adhered to. Currently, we are recycling the largest vessel ever built till date Ex Jahre Viking Ex Knock Nevis “ST MONT”. This has been made possible only because of good planning, excellent infrastructure and dedicated employees.<br />Company policy<br />Recycling facility Management Plan<br /> <br />Environment, Occupational Health & Safety Policy<br />We at PRIYA BLUE INDUSTRIES Pvt Ltd., which is a ship recycling unit are committed to continual improvement of our occupational health & safety and environment control processes aimed at prevention of all types of pollution and minimization of occupational health and safety risks. We shall strive to achieve these by:<br /> <br />Complying with applicable occupational health, safety and environment legislations.<br />Striving to achieve the occupational health, safety and environment objectives and targets as per Global Standards.<br />Communicating this policy to all employees and make it available to interested parties and public.<br />Upgradation with recent developing and innovative strategies, technologies, and health and safety standards to achieve best Safety and Health within the premises.<br />Procurement and use of best available Personal Protective Equipment, to achieve minimum accident rates and near misses.<br />Regular training and education of the workers for new trends in the field of safety and environment, usage of safety equipment and procurement of hi-tech instruments for safety. <br />Ship Recycling<br />Introduction<br />Ship recycling involves processing used materials into new products to prevent wastage of potentially useful materials, reduce / eliminate the consumption of fresh raw materials, reduce energy usage, reduce air pollution (from incineration) and water pollution (from land filling) by reducing the need for quot;
conventionalquot;
waste disposal, and lower greenhouse gas emissions as compared to virgin production. Recycling is a key component of modern waste reduction and is the third component of the quot;
Reduce, Reuse, and Recyclequot;
waste hierarchy.<br />Most ships have a lifespan of a few decades before there is so much wear that refitting and repair becomes uneconomical. Ship breaking allows materials from the ship, especially steel, to be reused. Equipment on board the vessel can also be reused.<br />Any industry basically aims at value addition. Generally the value addition is done through a 'building' process. However, ship recycling is a typical activity, which adds value through a 'recycling' process. When a ship goes uneconomic / unsafe as per standards of safety to operate, it is sent for recycling to ship recycling yards. At the same those ships that happen to meet with accidents and for whom the subsequent repairs prove to be uneconomic, are also send for recycling.<br />The contribution of the ship recycling yards is to generate value out of unusable ships by segregating it into various components that have their own economic value by subjecting it to a systematic recycling process.<br />Obviously, the net value addition out of ship recycling will depend upon the cost of doing it. Though western countries have developed superior technologies, which result into high productivity, Asian countries have come up with a low cost proposition for two reasons. One, relatively the manpower is cheaper in these countries combined with mechanized capability.<br />,[object Object],High technology uses more mechanized equipments and less labor, while the labor-intensive method combined with essential mechanized equipment (dominant at present) is able to do the job equally well. This together with a beach area large enough to accommodate the wide spread operations and good natural tidal support helps Alang recyclers to do the job satisfactorily. We have all these mentioned essentials and more in terms of necessary infrastructure to ensure compliance to all required statutory provisions under Indian law that includes correctly processing hazardous waste like Asbestos.<br /> <br />So even at a lower productivity rate, operations in these countries prove to be relatively cheaper. Hence ship-recycling industry has been diverted from western countries to India, China, Pakistan, Bangladesh etc. However, with many companies in India mastering the technology of identifying, removing safely and creating safe storage facilities for all types of hazardous wastes, we, who have certification from JAS ANZ-ICS India for ISO 9001 14001 and OSHAS 18001 as well as we have been accredited by TUV Rheinland India Pvt Ltd for ISO 30000 have become fully competent to tackle hazardous wastes with the help of consultants experienced in such business. We are fully utilizing the services of these companies for safe removal of hazardous wastes originating from the vessels coming for recycling and pay immense attention to labor safety & health. In fact, one such unit has been contracted by S.R.I.A (Ship Recyclers assn) who have accepted responsibilities for safe removal of Asbestos, PVC and other hazardous waste.<br />Value addition in ship recycling is done through what can be called quot;
a reverse processquot;
. Generally, the industries begin with labor intensive technology and gradually march towards sophisticated technology. But in case of the ship recycling industry, history suggests that it has reverted back to labor intensive technology, since the high tech proposition has proved more costly. Not only has the geographic base shifted from Europe to Asia, mainly in Seventies but within Asia also, the base has shifted from Taiwan to Indian sub-continent, since Taiwan also had made it a high tech proposition.<br />Environment Friendly Company Policy<br />Labour Safety Company Policy<br />www.nagarsheth.com/<br />profile<br />Nagarsheth Shipbreakers, is one of the leading pioneers of the shipbreaking industry in India. Nagarsheth Shipbreakers, played a crucial role in the creation of the Alang shipbreaking yard, which is one of the biggest shipbreaking yards in Asia.We have been a proud associate of various Governmental Organizations, playing a vital role in the policy-making decisions for the shipbreaking industry.Over the years we has procured and dismantled 40 ships, with a total tonnage of approximately 349000. Our existing capacity is 50000 LDT tones per year.From 1965 to 1983, our operations were carried out from Darukhana, Mumbai Due to the geographical limitations of Mumbai port, a maximum of 25 ships could be dismantled at a time. In order that India maintained a competitive edge, shipbreakers from Mumbai took an initiative and scouted the Western Coast of Gujarat and Maharashtra, to find a conducive site for the shipbreaking activities.Nagarsheth Shipbreakers played a lead role in the finalization of the Alang shipbreaking yard. THE EASTERN LEGEND, procured by us in the year 1983, was the first ship to be cleared by the Customs at Alang. Nagarsheth Shipbreakers , is a private organization. Each of our core members have carved a niche for themselves within the organization. They each play a specific role in ensuring that we remain a forefront player in the Shipbreaking Industry. Mr. Pravin Nagarsheth - Overall policy decisions Mr. Mukund Nagarsheth - Banking and Taxes Mr. Devang Nagarsheth - Yard Operations and Daily Sales Ms. Sonal Nagarsheth - Administrative operations. Our bankers since 1983, are the Bank of Baroda , Zaveri Bazar Branch, Mumbai.<br /> <br />Technology<br />Our yard at Alang is a 95 meters sea front, which is one of the larger yards. Initially under the quota system the yard was operative for only 4–6 months a year.But from 1992 with the Open Import Policy, Nagarsheth Shipbreakers, grew substantially and our capital investment needs also grew. The major requirements of this industry, are Capital, Labour and Gas. In the early years of the industry, all breaking activities were done manually. Over the years, keeping in mind our output and labour welfare, we at Nagarsheth Shipbreakers, have taken various initiatives in mechanizing our breaking activities. Mobile cranes are used for transferring scrap from the ship to the yard. A Golieth Crane which was specially designed as per our requirements, is an overhead crane for facilitating the movement of large pieces of scrap. This crane reduces the risk to the labourers, as it eliminates manual handling of this scrap. For the same purpose, trolleys and tractors, were also introduced at our yard by us. Specially fabricated Winch were brought in by us for carrying back and forth of the gas cylinders from the yard to the ship deck. By introducing special cases for the gas cylinders, we have effectively reduced our wear and tear of the cylinders.<br />www.sohamoverseas.com<br />www.hoosami.com<br />Hoosami Metal Industries Pvt. Ltd. is a ship recycling associated company engaged in the Marine field on the west and east coast of India. <br />Established in 1986, The Range of activities of the company extends to all Ship requirements for Deck and Engine stores, particularly Main and Aux Engines, Spares Crankshafts, Engine Parts, and other Marine Equipments. <br />The Company Maintains a large stock of Re-Usable Anchors, Chain, Cargo Gears, Cranes, Winches and Navigational Equipments obtained from Ship demolitions in India.<br />/www.aryashipbreaking.com<br />Welcome To Arya Ship Breaking Company Pvt. Ltd. <br />Arya ship Breaking Company (P.) Ltd. is one of the leading ship recycling units in ship recycling yard science last 20 years and authorized to recycling. Total area of the plot is 2340 sq. meters (52m*45m). Arya ship breaking Company (P.) Ltd. demolished 22 Nos. of different type of ships and MT of these ships are 2,49,538. We comprises of highly efficient team members with rich experience and well maintained as well as fully equipped plot with required infrastructure which do not pose health risk to the workers concerned or to the population in the vacinity. Such facilities can reduce, minimize and eliminate to the extent parcticable adverse effect on the environment caused by the ship recycling. Majority labour force has been trained for working activities; others will be trained in future dully needed Labour force has been decreased or increased with tonnage and type of ship on the basic of daily wages.<br />Click Here Download Our Recycling Plan<br />Arya ship Breaking Company (P.) Ltd. is member of TSDF site at Alang. All waste generated from recycling activities has been kept separate from recycling material and equipment, stored in appropriate condition and transferred to a waste management facility,which is identified by State Pollution Control Board. We will become member of CEPT at Allang and any commom incinerator facility authorized by State Pollution Control Board in Gujarat. We will be followed regulations,guideline and direction as under:<br /> Hon'ble Supeme court Direction daed 14-10-2003 and 06-09-2007<br />Gujarat Maritime Board Guideline july,2003<br />Hazardous Waste Management and Handling Rule 1989<br />Factories Act 1948<br />Air pollution (prevention and control) Act 1981<br />Water pollution (prevention and control) Act 1974<br />Petroleum Rules 2002<br />Explosive Act and Rules<br />Technical Guidance for environment sound management under IMO and ILO<br />Arya Ship Breaking Company(P.) Ltd.has established crtification and inspection procedure to to meet with national snd international standards. We are certified for,ISO 14001, OSHAS 18001. All dismantling activity of ship has been carried out in this plot. It consists of the followingl:<br />LAND AVAILABILITY FOR SHIP RECYCLING: We have been allotted a 52 meter plot by Gujarat Maritime Board. Irrespective of vessel we have the facility of recycling vessel up to the aggregate total of the width of the 52 meters keeping a distance of five meters from the boundry of the plot. Incase the aggregate width of ships crosses 52 meters; we shall procure NOC of a naighbor's plots. <br /> FACILITIES AT THE PLOT: 1) Basic necessities: Water closer, Urinals, Bathrooms and rest room will be provided at our plot for workers employed for the recycling activity with the stipulated time frame provided by the Hon'ble Spreme Court judgment (reference TEC report). we are in consultation with department of DISH for provisions in Factories Act for the same.<br /> 2) Asbestos Handling Facilities: Asbestos Management and Handling facility shall be raised within stipulsted time allotted in TEC report. Our plot have a separate Asbestos Stroge and asbestos handling room. <br /> 3) Personal Protective Equipment : We are committed to provide PPE to all the workers employed of our plot. If more workers are to be employed, suitable PPE will be procured before employing them. Cent percent PPE are available for employed workers and we shall procure more PPE before giving employment to workers. 4) Fire Safety: The basic firefighting facilities and equipments to handle the initial burst of fire (mentioned above) is available at the plot.In case the need airses, help will be taken from the fire fighting facility of Gujarat Maritime Board available at Alang itself.<br /> 5) Equipments for ship dismantling: The equipments/facility for ship dismantling is generally common for any class of ship which is already given above. Incase of dismantling of special class of ship depending on the type and tonnage, required equipments will be procured at the time of dismantling.<br /> WORKERS EMPLOYED AT THE PLOT : Our industries are secondary steel producing industries and not a recycling service providing industries. Irrespective of size of vessel or number of vessel the daily production of steel ranges between 50 metric tone to 70 metric tone. Thus the work force and facility requires need to be changed with increasing of size or vessels. Only thing that we vary is the time taken for project.Irrespective of the size and number of vessels, the workforce at our plot will change marginally considering that small vessels will take lesser time for dismantling and a bigger ship will take a longer time to do the same.<br /> MEMBERSHIP OF COMMON FACILITIES : We are committed to become a member of any facility (CEPT) to treating bilge water. We are already member of TSDF at Alang. The copy of authorization is enclosed herewith.<br /> FACILITY FOR NORMAL AND SPECIAL CONCERN SHIP : We are capable of recycling all kind of vessels including ship of special concern. We have facilities and expertise available at our plot. Further if any additional facility is required to be raised.We shall do that in line with provision of various Act exciting for ship breaking activities.<br />RECYCLING FACILITY MANAGEMENT PLAN<br /> (A) Environment, Occupational Health & Safety Policy. We at Arya Ship Breaking Company (P.) Ltd. which is a ship recycling unit are committed to continual improvement of our occupational health & safety and environment control processes aimed at prevention of all type of pollution and minimization of occupational health and safety risks. All practicable steps shall be taken to assess risk and safety status periodically for creating awareness amongst all employees and public at large, by using expertise knowlwdge of educated and trained personnel. We shall strive to achieve this by: 1. Complying with applicable occupational health, safety and environment legislations. 2. Striving to achieve the occupational health, safety and environment objectives and targets as per Global Standards.<br /> 3. Communicating this policy to all employees and make it available to interested parties and public.<br /> 4. Up gradation with recent developing and innovative strategis, technologies, and health and safety standards to achieve best Safety and Health within the premises.<br /> 5. procurement and use of best available Personal Protective Equipment, to achieve minimum accident rates and near misses.<br /> 6. Regular Training and education of the workers for new trends in the field of safety and environment, usage of safety equipment and procurement of hi-tech instruments for safety.<br /> Planning for Hazard Identification, Quantification.<br />Hazard identification and risk assessment is planned and the necessary implementation of the control measures, have been in practice for: <br /> Routine and non-routine activities<br /> Activities of all personnel having access to the workplace<br /> Facilities at the workplace <br /> (B) Planning for Risk Control of Safety, Health and Environment : <br />Sr. Risk Control Strategy 1 Work at Heights Experienced workers, availability if relevant fall arrestor systems, safety belts, fall protection sytems. 2 Fire & Ballast Availability of Fire fighting equipment, sand buckets and fire blankets, fire pumps, water tanks <br /> 3 Falling objects proper handling, proper training and availability of helmets and other relevant PPES .<br /> 4 Accidents due to Availability of proper lightings, and working darkness atmosphere, and emphasis on working in day light. Availability of flame proof lighting fixtures in closed and dark areas.<br /> 5 High degree labour Good and atrractive wages and good turnover facility and other incentive. <br /> 6 Confined Space Working Trainined confined space entry worker with relevant PPEs and Oxygen detectors.<br /> 7 Working in Flammable Proper labeling/ sign boards, working with Environment flame- proof tools and tackles, proper ventilation <br /> 8 Working toxic and Trained worker with relevant PPE's and corrosive atmospheres periodic atomsphere checks.<br /> 9 Gas cutting Proper eye protection glasses, ventilation PPE's compressed gas cylinder safety.<br /> 10 Crane Operation Proper load handling, inspection and trained operators.<br /> 11 Asbestos/ACM and other Trained workers, specific PPEs, ACM hand- Waste ling room, proper waste packaging bags, proper transporting to temporary as well as common landfill site.<br />www.sriaindia.com<br />Safety mearures<br />Use of PPE is made mandatory for workers by ship-recyclers.<br />Workers are regularly sent to the training centre for safety education.<br />Emergency treatment is provided by Red Cross Hospital.<br />Regular medical checkup camps are arranged by Ship-recyclers in co-ordination with GMB.<br />The accident rate has decreased considerably.<br />Health awareness camps are organized on regular basis.<br />Special workers are trained for handling of hazardous waste like asbestos.<br />Hoardings and slogans in local languages are displayed at various corners of the plot premises to keep reminding the workers regarding the safety.<br />Safety audit is conducted jointly by GMB and ship recycling industries association.<br />GMB and GPCB monitor the safety standards on regular basis.<br />Life buoys are kept on board the vessel during its recycling for emergency exit to the sea incase of fire.<br />Safety belts are provided to workers working on board the vessel.<br />Types pf waste<br />Hazardous Waste<br />USED / WASTE OIL<br />CONTAMINATED SAND WITH OIL<br />OILY SLUDGE<br />ASBESTOS<br />PAINT CHIPS<br />CABLES<br />BATTERIES <br />Non-Hazardous Waste<br />Glass wool and insulating material<br />Thermocol<br />PVC/Rubber wire-tubes<br />Ceramic/glass and Solidified cement<br />Bio medical waste<br />Kitchen waste<br />MSW waste<br />Interesting fact<br />PCB’s used in insulation and oil in transformer has been banned since 1976. Ships are regularly repainted during its life. Ships arriving for demolition after 1976 are repainted and therefore the question of presence of PCB in such ships does not arise at all. <br />As ships go for dry-docking and repainting the TBT containing paints, which have been banned since 2000, should be phased out slowly.<br />The pollution from the ships is not merely a part of the ship recycling activity. The anti-fouling paint wipes against the seawaters everywhere and even falls in the repair yards. If 4% of the vessels are scrapped each year then 25% of the vessels is put up in the dry dock for major overhauling. The paint blasting and repainting data should also be monitored. No hue and cry is created for the same at dry docking yards.<br />It may be noted that asbestos were used in all ships built before 1985. All ships built after 1985 may not contain asbestos, as it was banned in 1985. The presence of asbestos in ships coming for recycling is a temporary phenomenon. Therefore the issue of presence of asbestos in ships is transitory and minimal in nature. Alang is already recycling vessels built in 1981.<br />Apart from rare vessels with high asbestos content like steam turbine and passenger vessels, majority of vessels arriving at Alang for recycling contain only negligible quantity of Asbestos, ranging between 0.05 to 0.10 % of the total LDT of the vessel.<br />Handling of waste<br /> Ship-recyclers provide on-site collection, storage facility for the storage of waste. <br /> Ship-recyclers maintain the records of waste generation, storage, treatment and disposal. <br /> The workers are provided with PPE’s when they collect the waste generated from the vessel. <br /> Plot holders display all the information of waste generated on the board outside the plot premises. <br /> GCPB issues decontaminate certificate only after ensuring the safe handling of waste generated. <br /> Oil obtained from ships is sold to MoEF registered traders. The residue is collected and sent to the TSDF site at Alang. <br /> A substantial portion of cable retrieved from vessels is sold to as it is for re-use purpose. And the remaining portion of cable is either stripped by ship-recyclers for recovery of non-ferrous metals like copper or is sold to GPCB registered recyclers. A part of rubber and plastics obtained by stripping is sold as recyclable material and the remaining waste is disposed off at TSDF site. <br /> Glasswool, thermocol, kitchen waste and other waste collected from the vessel is sent to TSDF at Alang. <br /> Water pumps are arranged at plot and on board the vessel for pre-caution.<br />](https://image.slidesharecdn.com/shipbreakingdata-110717031052-phpapp02/85/ship-breaking-data-1-320.jpg)
