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COATING ISSUES AND ITS IMPLEMENTATION

BY REGULATIONS —UNTHOUGHT FOR


DECADES , BECOMING REALITY

Narayana Prakash Kamala Krishnan .P.G.


Project Manager [New Builds] Coating Surveyor [New Builds],
G.T.R.C.Marine Consultants, Nassau, Bahamas G.T.R.C.Marine Consultants, Nassau, Bahamas

ABSTRACT: this way it could be possible to extend the safe life of the
vessel.
Corrosion protection of ships in the marine environment
has challenged for years in the areas of their hulls and Remember a Deck Cadet or Seaman chipping on the deck
internal tanks. The coating process has long been receiving for rust. Introduction of PSPC regulates the activities by
less attention compared to other engineering activities that procedural methods for which systematic training and
go into the construction and maintenance of ships. This is process for coating application are becoming mandatory.
RIWHQUHÀHFWHGE\WKHUHODWLYHO\VORZGHYHORSPHQWLQFRDWLQJ
This paper discusses the coating standards including surface
and surface preparation technology in comparison to other
preparation and coating application for the purpose of
shipyard engineering processes, and the lack of hard data
enhancing the safety, performance and life of the ships.
on installation and subsequent maintenance of the coating
system. INTRODUCTION
In 2006, as a means to minimize early corrosion failure of The requirement of the IMO PSPC regulations for ballast
ships and further to enhance Maritime safety, IMO proposed tank coatings includes the creation and maintenance of a
a mandatory resolution commonly referred to as the FRDWLQJVWHFKQLFDO¿OH &7) FRQWDLQLQJLQVSHFWLRQUHFRUGV
Performance Standard for Protective Coatings (PSPC) for IRUWKHEDOODVWWDQNVFRDWLQJKLVWRU\IURPVWDUWWR¿QLVK
Ballast tanks of Newly built ships to satisfy target useful life To organize it in a timely, cost effective manner, digital
of 15 years. inspection data can be stored and retrieved during the coating
process so that it eases the building of the ship without extra
The PSPC rules are new and unproven concepts which
work on the inspectors.
call for rigorous incorporation of reality based evidences
currently available since there is limited practical experience The regulation is intended to ensure that the coatings on
in terms of the validity of the PSPC. ballast tank to achieve a target life of 15 years and coating
inspection processes are fully documented in CTF- kept
7KHOLIHWLPHRIDVKLSLVJUHDWO\LQÀXHQFHGE\WKHFRUURVLRQ
on board of the ship at the completion of the building. In
FRQGLWLRQV SDUWLFXODUO\ LQ WKH EDOODVW WDQNV 7R IXO¿OO WKH
addition the performance of the coating system is a condition
demand for a long service life, the water ballast tanks should
of class under the Enhanced Survey Program (ESP). With the
ideally be protected with a high-quality coating system
PSPC is incorporated in the SOLAS regulations the issues
correctly applied at the new building stage.
becomes even more important, indicating the performance
After delivery of the vessel a regular inspection and the ballast tank coating as critical to the safety of life at sea,
maintenance plan should be followed where any damage, DVLPSRUWDQWDV¿UH¿JKWLQJHTXLSPHQWVRQERDUG2QHNH\
ZKHQREVHUYHGLVUHPHGLHGXSZLWKDVSHFL¿HGFRDWLQJ,Q aspect of the PSPC requirement is the need for the shipyard

28 MARINE ENGINEERS REVIEW (INDIA) March 2011 www.imare.in


to deliver the vessel complete with is to follow the vessel through its  6SHFL¿HG WKLFNQHVV WR EH FRDWHG
a CTF. This SOLAS document is service life. in acceptable atmospheric
aimed at providing a record of the 4. To provide a 15 year or more life conditions.
coating history for the ballast tanks IRU EDOODVW WDQN FRDWLQJV GH¿QHG Quality Assurance in Today’s
from the application of shop primer, as being in ‘good’ condition Shipyards:
through to the delivery of the vessel. (resolution A.744(18)).
 *RRG¶ FRQGLWLRQ LV GH¿QHG LQ ‡ 6FLHQWL¿F DSSURDFK LQDGHTXDWH WR
The IMO resolution MSC.215(82) resolution A.744(18) and is “ SURFHVV DQG  IDFLOLWLHV  WUDLQHG
or PSPC in sea water ballast tanks minor rust spotting affecting < 3% personnel
KDVUDLVHGFRQVLGHUDEO\WKHSUR¿OHRI and < 20% of welds and edges” ‡ &DOFXODWLRQHUURUV
coating activities in yards, owners and 6. Better coating systems with less ‡ 2XWRIVSHFUHDGLQJDFFHSWDQFH
regulatory authorities. The prospect maintenance ‡ 2YHUZULWHVRIGDWD
of additional IMO resolutions on 7. Improved safety at sea. ‡ 8QUHDGDEOHGDWD
coatings to deal with other critical
WHY BALLAST TANKS: ‡ 6LJQDWXUHV E\ XQTXDOL¿HG
areas in vessel are attracting the
inspectors
attention of many people. Ballast water tanks are a very
MHRSDUGL]HG DUHDV RQ VKLSV (I¿FLHQW ‡ 7UDQVFULSWLRQHUURUV
THE NEED: AIMS OF PSPC coating in these tanks can improve ‡ (QYLURQPHQWDO FOHDQOLQHVV
VKLSV VDIHW\ DQG SUR¿WDELOLW\ %DOODVW conditions are not available/
This mandatory standard applies to ignored due to pressure on delivery
tanks are very susceptible to corrosion
coating of ballast tanks in all ships schedules.
due to their constant wet and dry
above 500 GT as well as double-
conditions when the ship is ballasted Coating manufactures recommend
side skin spaces on bulk carriers,
or carrying a full cargo. Apparently QRPLQDOGU\¿OPWKLFNQHVVYDOXHVIRU
and is an effort to protect the marine
FRDWLQJVSHFL¿FDWLRQVRIWKHVKLSVIRU which the properties of their coating
environment and seafarers. The aim
Water Ballast Tanks at New Building apply, such as adhesion and other
is to ensure the structural integrity
don’t satisfy 15 years of coating life. performance properties. In some cases
of the vessel as a whole by avoiding
maximum thickness values should
the catastrophic effects of corrosion, Shipyard Problems ?
not be exceeded to prevent cracking
thereby improving marine safety in
Today the surface preparation and and other failure phenomena. Owners
general.IMO PSPC needs following:
coating process is considered by most SUHSDUH VSHFL¿FDWLRQV RQ WKHVH
1. Coating system must be type shipyards as a ‘bottleneck’ in the guides. This means that a record of
DSSURYHG E\  FODVVL¿FDWLRQ process of Blasting and Coating. WKH VSHFL¿HG FRDWLQJ DQG WKH FRDWLQJ
society . process is essential when preparing
2. The coating inspectors are The application process must be
and carrying out inspections.
IRUPDOO\ FHUWL¿HG )526,2 controlled with respect to the anti-
NACE or similar) FRUURVLRQ FRDWLQJ WKDW LV ¿W IRU WHAT DOES IMO PSPC
3. Documentation for all work purpose. CONSISTS OF?
related to the coating of the 1. The substrate must be correctly 1. Type approval of the coating
ballast tanks is compiled in a CTF prepared to standard cleanliness system.
(Coating Technical File), which DQGSUR¿OH 2. Technical Requirements (Coating
data sheets, detailed application
process).
 9HUL¿FDWLRQ DQG ,QVSHFWLRQ DQG
documentation of coating process.
4. Documentation - Coating
Technical File (coating history)-to
be maintained onboard.
THE PARTIES INVOLVED:
In all new building contracts today for
building and painting a ship the parties
involved are:
– Ship-owner
– Shipyard
From a situation like this to----- To Like this –under construction and to
last for at least 15 years – Maker [Coating ]

MARINE ENGINEERS REVIEW (INDIA) March 2011 www.imare.in 29


WHAT THEY NEED: Coating Manufacturer : Date Event
‡ (QVXUH W\SH DSSURYHG FRDWLQJV WR
Ship-owner : SOLAS XII/6.3 comes
the shipyard. 1st July 2006
into force
± $YHVVHOEXLOWWRVSHFL¿FDWLRQDWDQ ‡ 6XSSO\ QHFHVVDU\ 7HFKQLFDO
agreed price and delivered at the support data sheets(application 8th Dec 2006 Draft resolution adopted
agreed time and process
Applied to all ships of
parameters, maintenance procedure 1st July 2008
– IMO PSPC complied coatings in not less than 500GT.
after delivery etc,)
ballast tanks to give trouble free
‡ &RQWLQXRXV 5 ' IRU EHWWHU Will apply to all Keels
good performance for 15 years or 1st Jan 2009
coatings. laid after this date
more.
‡ &RQWLQXDOO\ XSGDWH UHJDUGLQJ
Consequences for the Ship Owner: Will apply to all vessels
coating Technology to Shipyards. 1st July 2012
‡ ([SHFWHGWKDWQHZEXLOGLQJSULFHV delivered after this date
5ROHRI&ODVVL¿FDWLRQ
may increase by about 3-5%.
‡ +DYH WR PRQLWRU DQG PDLQWDLQ ‡ $SSURYLQJ RI SUHTXDOL¿FDWLRQ IMPLEMENTATION DATES
ballast tank spaces. tests and issuance of a Statement In adopting resolution MSC.215(82),
‡ +DYH WR UHZULWH WKHLU VWDQGDUG of Compliance or Type Approval the Performance Standard for Protective
SDLQW VSHFL¿FDWLRQV WR UHÀHFW WKH &HUWL¿FDWHIRUFRDWLQJV\VWHPV Coatings (PSPC), on December 8,
regulations. ‡ &KHFN 7HFKQLFDO 'DWD 6KHHW DQG 2006, the International Maritime
‡ 0DLQWDLQFRDWLQJWHFKQLFDO¿OHRQ the Statement of Compliance or Organization (IMO) mandated the
board the ship. 7\SH$SSURYDO&HUWL¿FDWHFRPSO\ coating of dedicated seawater ballast
‡ %HQH¿WV ± ORQJHU VHUYLFH OLIH RI with this Standard, In short tanks for all new ships of 500 gt or
vessel. more and the coating of double-sided
Consequences for the Shipyard: skin spaces of bulk carriers of length
equal to or greater than 150 meters.
‡ 7R KDYH DQG LPSOHPHQW VFLHQWL¿F The PSPC will come into effect for
approach for coating activities. ships which are contracted on or after
‡ 7R EXLOG DQG GHOLYHU YHVVHOV ZLWK July 1, 2008; or, in the absence of a
IMO compliance. building contract, the keels of which
‡ 7R PDNH D SUR¿W LQ GRLQJ VR LQ are laid on or after January 1, 2009;
most cases!) or for vessels to be delivered on or
‡ 6KLS\DUGV REOLJDWLRQ LQ SUHSDULQJ after July 1, 2012. (although it was
tripartite agreement between introduced under the International
‡ 7KUHHSDUWLHV RZQHUVKLS\DUGDQG $VVRFLDWLRQRI&ODVVL¿FDWLRQ6RFLHWLHV
coating manufacturer) (IACS) Common Structural Rules in
‡ &RDWLQJ LQVSHFWLRQ E\ FHUWL¿HG ,Coating Application. January 2008).
coating inspector. ‡ &KHFN  FRDWLQJ LQVSHFWRU LV
Usually shipyards, owners and
‡ 3UHSDUDWLRQRI&7) /RJERRN TXDOL¿HG LQ DFFRUGDQFH ZLWK WKH
operators have a long lead time to
‡ ,QFUHDVHLQFRQVWUXFWLRQWLPHWREH TXDOL¿FDWLRQVWDQGDUGVLQWKH,02
fully grasp the technical and cost
managed. PSPC,-Inspection of Coating.
implications of new legislation; in the
‡ 5HYLHZ RI WKH &RDWLQJ 7HFKQLFDO
‡ 6HWWKHFRUUHFWFRDWLQJSURFHVVDQG case of the PSPC they did not have
File (CTF).
procedures to meet the standard. this advantage..
‡ 7UDLQWKHFRQWDFWRUVPDQSRZHU Where do we stand now:
We can see that only the Builder and WHAT IF THE DEADLINE IS
‡ 0RGLI\  DXJPHQW XSJUDGH CROSSED?
Owner were interested in the coating
required new facilities.
program in any New Buildings as on IMO has published a circular- MSC.1/
‡ 4XDOLI\VWDIIWR1$&()526,2
now for Pre-PSPC vessels. The Role Circ.1247 dated 6th November 2007
or equivalent.
of Class was missing in many cases UHJDUGLQJ 8QL¿HG LQWHUSUHWDWLRQ RI
‡ ,QVSHFWLRQ UHFRUGV HOHFWURQLF  WR but with the PSPC implementation, “Unforeseen Delay in Delivery of
be auditable. Inspection, Witness and Review will Ships” adding specially to application
‡ 6HOHFW RQO\ 7\SH ±DSSURYHG FRPHLQWRSLFWXUH6RPHFODVVL¿FDWLRQV scheme in SOLAS regulation II-1/3-2.
coating systems societies have already incorporated
‡ 3UHSDUH D &7) &RDWLQJ The Delay in delivery is due to
in their Quality policies, regarding
Technical File) and Records to be unforeseen circumstances beyond
Inspection in their Quality Assurance
retrievable. the control of the builder and the
Programme.
30 MARINE ENGINEERS REVIEW (INDIA) March 2011 www.imare.in
owner , may be accepted be blasted off.
by the Administration ‡ 6KDUS HGJHV WR EH JURXQGHG WR
stating that the unforeseen 2mm radius.
circumstances beyond the ‡ 7KHUHWDLQHGDSSURYHGVKRSSULPHU
control of the builder and to be sweep blasted / high pressure
owner .In such a situation washed or prepared by equivalent
the delivery date annotated cleaning method.
on the passenger ship ‡ 1R YLVLEOH GXVW RLO GLUW VKDOO
VDIHW\ FHUWL¿FDWH FDUJR remain.
ship safety construction Surface Preparation after
FHUWL¿FDWH RU FDUJR VKLS Erection:
VDIHW\FHUWL¿FDWHVKRXOGEH ‡ 1R YLVLEOH GXVW RLO GLUW VKDOO
foot noted to indicate that remain.
the ship is accepted by the
‡ (UHFWLRQ MRLQWV DUH WR EH SRZHU
administration under the
tooled to St 3 or more.
unforeseen delay.
Courtesy: Masanori Yoshida, Japan Ship Technology Research ‡ &RQWLQXRXVGDPDJHPRUHWKDQ
&ODVVL¿FDWLRQ VRFLHWLHV Association m2 or 2% area to be blasted to Sa
like DNV recommend ‡ 3UHSDUH&7) 2 ½.
planning for compliance with PSPC
if delivery date is close to the cut off Minimum requirements of CTF: ‡ &RDWLQJV RYHU ODSV DUH WR EH
date delay might push the delivery past ‡ 7\SHDSSURYDOGRFXPHQWV feathered using papering / disk
the cut- off date. Yards and owners grinding.
‡ 7HFKQLFDOGDWDVKHHWVRIFRDWLQJV
should include a clause in the contract THE INSPECTION PROCESS:
long series of sister ships for how to ‡ 3URFHGXUH IRU UHSDLU GXULQJ QHZ
deal with possible requirements not building SOLAS Regulations II-1/3-2----
in force or not known at the date of ‡ /RJVKRZLQJFRDWLQJGRQHDVSHU PSPC CHALLENGES:
signing the contract. VSHFL¿FDWLRQ
‡ 6KRXOGUHVXOWLQ,PSURYHGGHVLJQ
Including inspection report, ‡ $ JUHDWHU QHHG IRU TXDOL¿HG
Instruments to meet Target of IMO
completion dates, inspection inspectors
PSPC:
remarks, results with relevant ‡ $JUHDWHUGHPDQGIRUHGXFDWLRQLQ
The PSPC sets out requirements for signatures. coating management
improved procedures of coating water ‡ 'HWDLOVRIPDLQWHQDQFHDQGUHSDLU
‡ $ PRUH V\VWHPDWLF DSSURDFK WR
ballast tanks and better quality control of coating during service
inspection (objectivity)
by increased inspection requirements PSPC requirements
at all stages within surface preparation, ‡ 1HZ WHFKQRORJ\ VROXWLRQV IRU
Primary Surface Preparation: equivalent systems
coating application and coating
quality. ‡ 7\SHDSSURYHGVKRSSULPHU ‡ ,QFUHDVHG DXWRPDWLRQ DQG FRQWURO
‡ 6WHHO WR EH EODVWHG WR QHDU ZKLWH of processes
‡ 8VHRIW\SHDSSURYHGFRDWLQJV
PHWDO 6Dò ZLWKDSUR¿OHWR ‡ %HWWHUGDWDUHFRUGLQJ UHWULHYDO
‡ :ULWWHQ WULSDUWLWH DJUHHPHQW
75 microns. ‡ 0DQDJHPHQWWRROV
(builder owner, maker)
‡ $WDQ5+OHVVWKDQDQGVWHHO
‡ 6XSHUYLVLRQE\TXDOL¿HGLQVSHFWRU
temperature 3 degree above dew
‡ 0RQLWRULQJ E\ FODVVL¿FDWLRQ
point.
society.
‡ :DWHU VROXEOH VDOWV PHDVXUHG DV
‡ 3UHSDUH&7)
sodium chloride </= 50 mg/ sq
Effects of PSPC on shipbuilding m.
yards: Surface preparation during block
stage.
‡ <DUGWRVHOHFWW\SHDSSURYHGSDLQW
Courtesy: Jotun Paints
‡ 'DPDJHGDQGZHOGWREHEODVWHG
‡ 7R KDYH TXDOL¿HG H[SHULHQFHG
WR 6D  ò  ZLWK SUR¿OH  WR 
inspectors GAP ANALYSIS:
microns.
‡ ,QYHVWPHQWV UHTXLUHG IRU QHZ ‡ :DWHU VROXEOH VDOWV PHDVXUHG DV The main objective of the gap
facilities if needed. sodium chloride </= 50 mg/ sq m. analysis is to assess yards’ current
‡ 6WDQGDUGL]HSURFHVVDQGSURFHGXUH ‡ ,I WKH VKRS SULPHU LV QRW W\SH coating practices, identify problems
without time delays. approved minimum 70% of it to and provide timely technical advice
MARINE ENGINEERS REVIEW (INDIA) March 2011 www.imare.in 31
18. GMMCO
Limited
- Full Page
Colour

32 MARINE ENGINEERS REVIEW (INDIA) March 2011 www.imare.in


for yards to improve in order to meet shipyards and subcontractors are a cleaning and draining and drying of
PSPC requirement. The gap analysis common feature of shipbuilding and the space.
looks at every stage of the coating are now an emerging theme in the Countermeasures played by
process: commercial market. The complexities Designers to some extent:
‡ FRDWLQJ IDFLOLWLHV SULPHU VKRS of the information exchange between
shipyards and subcontractors, and 1. Less Block Joints to be located
blasting and painting cells in ballast tanks, as it is impossible
‡ FXUUHQW SUDFWLFH RI VXUIDFH WKH QHHG IRU GH¿QHG DQG HIIHFWLYH
to avoid block joints in ballast tanks.
preparation and coating ZRUNÀRZV LQFOXGLQJ DQ HIIHFWLYH
This can help in smaller vessels.
application engineering change management
2. Simplify the structural details in
‡ 363&GRFXPHQWSUHSDUDWLRQ process, are crucial.
ballast tanks: arrange stiffeners on
‡ LQVSHFWRUWUDLQLQJ FINAL SOLUTION: the exterior side of tank boundary if
‡ TXDOLW\ DVVXUDQFH DQG TXDOLW\ possible.
control procedures. 3. Use shape and section steel like
Correctly understanding the PSPC bulb plates and inverted angles instead
requirements and identifying and of built up sections to reduce the time
closing any gaps between current consuming edge grinding treatments.
practice and the required standard 4. Lightening holes to be greater than
is critical for a shipyard. It should 400mm and drain holes to be as large
also be emphasized that compliance as possible.
with PSPC is not only a task for the WHAT NEXT?
yard’s painting department; good Improving the Coating Standards:
The notations are a response to the
structural design, co-ordination of The new regulation is stringent and International Maritime Organization’s
different production departments may have a great impact on shipyards. (IMO) recently adopted Performance
and management and supervision Corrective measures are to be taken at Standard for Protective Coatings
of production processes are equally the planning / design stage to improve (PSPC) for water ballast tanks and
important and relevant. surface treatment and coating without to the imminent adoption of other
Shipbuilders face a number of strategic affecting productivity. coatings standards for void spaces,
pressures to deliver ships in a shorter cargo oil tanks and through-life
1. The shipyard may adopt process maintenance of coatings.
timescale, of increasing complexity
plant type coating application
and modularity, to demanding Changing Mindset to Structured
process.
environmental rules, whilst lowering Approach:
initial build and operating costs. 2. Improving ship design by increasing
size of scallops, uVLQJ UROOHG SUR¿OHV With the Implementation of PSPC
One strategy for achieving these every shipyard must have its own
objectives is to keep partners more avoiding complex geometric
Performance Improvement Program
closely linked throughout the supply FRQ¿JXUDWLRQV DQG HQVXULQJ WKDW
which envisages:
and process chain. It is stated that WKH VWUXFWXUDO FRQ¿JXUDWLRQV SHUPLW
partnerships between customers, easy access for tools and to facilitate 1. Evaluate the applied technology

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MARINE ENGINEERS REVIEW (INDIA) March 2011 www.imare.in 33


and practices against the GOAL-BASED STANDARDS 6. UI SC 223 “For Application of SOLAS
International best practice. PSPC will set up an internationally Regulation II- 1/3-2 Performance
2. Identify gaps and imbalances in accepted approach for enhancing Standard for Protective Coatings
the existing system. safety of life at sea and protection of (PSPC) for Dedicated Seawater
the marine assets and environment. It Ballast Tanks in All Types of Ships
3. Identify areas that require prompt ZLOO DOORZ ÀH[LELOLW\ LQ HOLPLQDWLQJ and Double-side Skin Spaces of Bulk
attention. competition on scantling and safety Carriers, adopted by Resolution
4. Generate a prioritized performances standards. It will be a challenge in MSC.215(82)”.
plan. all developing regulations, standards 7. MARITIME SAFETY COMMITTEE
If not developed at this incipient stage and operational practice under the 84th session Agenda item 11, MSC
IRU *UHHQ¿HOG VKLS\DUGV WKHQ WRXJK framework of GBS which is open to 84/11/6 -Ship Design and Equipment
time is awaiting with Regulation innovation.  'HVLJQRI*UHHQ¿HOGVKLS\DUGLQ,QGLD
by Narayana Prakash, GTRC, Marine
enforcements. Existing Shipyards to References: consultants Ltd . page 29-30,39
expand vision based on PSPC. 1. 17th international ship and offshore IMARE(I) March 2010.
Ship Owners Goals structures congress 16-21 august 2009
9. Guide to Ballast tank protection—
‡ $FKLHYHD\HDURUPRUHXVHIXO Seoul, Korea volume 1 pg-23-25.
Jotun Ppt - Renate Hegna,slide 49
coating life 2. Coating Performance Standards-A
10. IMO resolution MSC.215(82)
‡ (QVXUH WKH\ NQRZ KRZ WKH VKLS UHYLHZVD¿QDK
About the Authors:
was constructed  8QL¿HGLQWHUSUHWDWLRQRI XQIRUHVHHQ
Narayana Prakash is Ex-Chief Engineer
‡ (YDOXDWH TXDOLW\ RI 6KLS\DUG delay in delivery of ships) MSC.1/
who is now working as Project Manager
Preservation efforts CIRC.1247dated 6th Nov 2007
[New Buildings] with GTRC Marine
‡ %DVLV IRU HYDOXDWLQJ TXDOLW\ RI 4. Comments from Japanese Shipyards,
Consultants, Ltd,Nassau Bahamas, for
coating application Masanori Yoshida. Japan Ship
a Project at Bharati Shipyard, Ratnagiri.
‡ 'DWD LQ DQ HOHFWURQLF IRUPDW Technology Research Association.
He is Fellow of Institution of Marine
3DSHUOHVVGDWD¿OH PPT
Engineers.
‡ +DYH PHDQLQJIXO SUHVHUYDWLRQ  6D¿QDK&RDWLQJ 3HUIRUPDQFH
Mr. P.G. Kamala Krishnan is working as
management tool Standard-A Review- PCE - PSPC
Coating Surveyor with GTRC Marine
‡ 0LQLPL]H OLIH WLPH SUHVHUYDWLRQ Workshop ,Amsterdam February 2007
Consultants, Ltd for a Project at Bharati
costs. Session 1-slide 36
Shipyard, Ratnagiri.

34 MARINE ENGINEERS REVIEW (INDIA) March 2011 www.imare.in

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