Syncrolift frequently asked questions

The Syncrolift^® shiplift concept has been designed to accommodate other shipbuilding/ship repair activities as required by individual customers.

The unique modular concept of the platform allows a purpose-built Syncrolift to be adapted for shaft removal, rudder repairs and to allow work on various underwater projections where appropriate.

A Syncrolift has also been used in conversion projects using the platform itself to raise or lower discrete ship sections. The Syncrolift itself can also be designed to act as a manipulator of hull sections.

Several installations have been constructed which utilise the Syncrolift^® technology for non-shiplifting duties. One application has been the raising and lowering of elevating ferry ramps, popular in areas where very high tidefalls make the match-up of ramps to ferry decks a problem.

Another application has been to provide a launching facility for large concrete caissons being constructed for breakwaters, barrages or bridges. These installations often have capacity requirements in terms of tonnes per unit length far in excess of any normal shiplifting demand.

Once the caisson building project has been completed, the hoists are usually configured into a more conventional shiplift. Other applications include the space industry, use as onboard ship elevators and as an alternative to canal-locks – where ship and the water it is floating in are lifted simultaneously. A wide variety of other usages have been studied and developed for use:

Ramps for Ferries
Syncrolift linkspans offer several advantages over other types of ramp systems:

• Syncrolift hoists are not limited in vertical travel and can accommodate any range of tidal variation
• Simple pushbutton controls stop the ramp at any height, so additional boarding ramps or systems are not required to handle vessels with different door heights
• Unlike hydraulics, Syncrolift systems are environmentally friendly and pose no risk of spilling hazardous materials into a waterway
• The system is always clear of the water for inspection and maintenance, and is not subject to wave damage from severe weather

Caisson Lifts
Using the same principles that make Syncrolift shipyards successful, the Syncrolift caisson lift and transfer system transforms a single shore berth into a multiple-berth construction site. Now several caissons can be under construction at the same time using efficient production line processes and quality control methods, and then transferred to the shoreside berth only for testing and launch. Customers using Syncrolift caisson lifts have achieved productivity gains of 300%.

Syncrolift caisson lifts are also recyclable - after use as a caisson lift, the unit can be reconfigured as a standard shiplift, or relocated for continued work as a caisson lift.

Bargelifts
Developed as an alternative to conventional locking systems, the Syncrolift system, called Bargelift, uses hoists and power to lift and lower vessels rather than water. A natural extension of Syncrolift shiplift technology, the Bargelift uses a lifting chamber instead of a platform.

A vessel (or towboat and barges), sails into the chamber, and is lifted or lowered while afloat -rather than being removed from the water. By keeping the vessels afloat, the Bargelift is able to match or exceed the throughput capacity of a lock system.

Benefits 

• Cost - Supported by standard piles that can be driven in open water, there are far fewer requirements for temporary installations to dry out the work area. In a traditional lock, that cost can approach 40% of the total project!
• Environmental - Bargelift does not use water for its operations, so there is no water depletion or water surge that would normally accompany the gather and release of millions of gallons of water with each operation.
• Inspection - Bargelift is removed from the water during its normal course of operations, hence, omitting the need to shut down the system for standard inspections or reviews.

Syncrolift^® shiplifts are designed for the dry-docking of vessels. The customer must identify the size and types of vessel that are planned to be drydocked in terms of vessel type, length overall, blocking length, beam, docking weight and draft.

Once this information is available, we custom design the Syncrolift using standard components wherever possible. We have extensive vessel data files and can often assist customers in developing the necessary data.

It is often practical to consider the installation of the Syncrolift^® in several phases. An initial phase, which will generate revenue to help finance or justify a larger installation, is very common. These initial installations are designed to be enlarged to greater capacities either by adding hoists at the seaward end, or by adding intermediate hoists to increase the shiplifts lifting capacity.

We are very sensitive to the needs of shipyards who are often initially unable to commit funds to construct their ultimate Syncrolift, but who wish to take a first step toward that goal. We have developed many strategies to accomplish a phased solution, and would be pleased to work with prospective customers on that basis.

A Transfer System maximises the productivity of the Syncrolift^® by adding additional shore-berths, which means more potential earning power.

For example, one Syncrolift plus three shore-berths provides the same number of dry berths as four floating docks, graving docks or slipways at a fraction of the cost per berth. A recent study has shown that three or more shore-berths can be provided, each at less than 50% of a single berth cost, adjacent to the Syncrolift. Seven or more berths were estimated to cost less than 25% of the single berth cost.

In addition, two or more smaller ships can be placed in one berth, further maximising a flexibility that conventional systems cannot provide.

Where space permits, we recommend our standard two level transfer system. This system meets all of the desirable shipyard transfer criteria, and is still the most cost effective. It is fast, safe and permits vessels to be moved to and from shore berths totally independent of other vessels in the shipyard. Transfer between the Syncrolift^¨ and any shore berth can often be accomplished in less than half an hour.

This system utilises a modular end transfer cradle, which is assembled to suit the ship to be drydocked. These cradle assemblies are quickly configured by connecting a combination of keel support modules and keel/bilge support modules into a cradle of appropriate size.

This cradle moves the ship longitudinally on rails, rolling on a series of specially designed high capacity low profile wheels, which are mounted to the underside of the cradle modules. A side transfer carriage, recessed in a pit so that rails on its upper surface can align with the longitudinal transfer rails at the shipyard grade level, is provided.

The end transfer cradle carrying the ship is moved onto this carriage. The carriage is moved laterally, carrying the ship and transfer cradle to align with rails at the designated shore berth. Once aligned, the ship can be moved into the shore berth. Only one side transfer carriage is required for the shipyard, but an end transfer cradle will be required for each active shore berth.

Due to the low coefficients of friction (1-1.5%), yard vehicles such as tractors or light cranes usually provide the necessary power for vessel transfer. Single level transfer systems are also often specified. The simplest version works very similarly to the two level systems except that side transfer involves a step whereby the side transfer vehicle must physically lift the end transfer cradle wheels clear of the ground for transfer, rotate them 90¡ and lower them for transfer into a shore berth.

The towing criteria are much the same, but the lifting and lowering steps add to the process. We have supplied more complex transfer systems for special applications, including the transfer of nuclear submarines. These systems often fulfill functions beyond the mere transfer of ships, such as the manipulation and alignment of hull modules during assembly. Should you have special transfer system requirements, our engineers will be pleased to develop a custom solution to your problem.

Each shipyard has its own unique environment and operating requirements. The best transfer system is the one that maximises the earning potential of your facility.

We have extensive experience with a wide range of different systems and can help you choose the one that best suits your budget and needs.

In theory there are no limits. The only real constraint is a function of the size of ships to be docked and the total available space.

One of our existing Syncrolift^® installations currently supports a facility with 40 adjacent repair berths, and frequently docks/undocks at less than hourly intervals, docking around 2,000 vessels a year. Almost every modern Syncrolift® in service today has an adjacent multi-berth facility, which it supports. The platform itself is always available for an emergency dry-docking.

The modern Rolls-Royce Syncrolift^® incorporates the patented ATLAS Dockmaster (Advanced Technology Loading Articulated Shiplifts) system as standard. ATLAS assists the shipyard Naval Architects and docking personnel obtain important additional information on the docked vessels.

It also gives an operator the potential to use the installation for operations beyond the conventional docking or undocking of ships. The patented ATLAS Dockmaster system provides the operator with a range of information that no other drydocking system can provide.

The operator is therefore able to take action to protect both the ship being lifted and the lifting equipment. Other drydocking systems focus on the safety of the shiplift only. The ability to analyse and record vessel information means that the shipyard can offer customers a continuous service record, and provide comparisons of loading data over the life of a vessel and/or between docking and undocking.

Some special features of the ATLAS Dockmaster system are: 

• Display of ship’s applied load distribution on the platform.
• Automatic calculation and display of the location of the ship’s longitudinal centre of gravity and transverse centre of gravity. 
• Automatic calculation and display of offset loads on the platform by the ship. Display of the ships load distribution.
• Automatic platform cycling, and the calculation and display of individual hoist rope system efficiency. A tool for reducing servicing requirements and monitoring maintenance regime effectiveness. The results are recorded and printed. A printed record of each operation will be produced periodically, indicating the date, the time, operating mode and platform depth and loading on each hoist. In the event of a fault, an automatic printout will record the time of occurrence, platform depth, loading on each hoist and list of fault codes, which will show the conditions at all mentioned points as well as the fault or faults that stopped the operation. Print screen feature provides a printed copy of the graphic image on the monitor, on request. The package includes all necessary software, a high quality printer with interface adapter and input buffer.
  The system is PC based using conventional hardware. This means that most components can be obtained locally.
  

A Syncrolift^® shiplift like any mechanical device requires regular maintenance in order to maximise service life. Years of experience has proven that those shipyards that invest the time and resources in preventative maintenance minimised down time, and realise totally reliable and safe performance from their Syncrolift installation.

It is highly recommended that a named individual within the shipyard be assigned the responsibility and authority for shiplift maintenance. Typically maintenance procedures are as follows:-

Maintenance Categories

The Syncrolift Platform

• Weekly - lubricate lower sheaves
• Annually - Inspect for cracks and corrosion.
• Weld repair and coatings repair as required.
• Replace damaged wood decking

Hoists

• Weekly - lubricate exposed gears
• Quarterly - check gear oil level
• Lubricate upper sheaves
• Semi-annually - clean brakes, lubricate pawl linkages, limit switches, pillow blocks
• Annually - check pawls, gear line-up, clean and inspect brakes, strip and renew some lower sheave bearings
• Two year - repaint hoists if necessary, drain and flush gearbox
• Four year - examine flexible coupling
• Eight year - strip and renew one set of upper sheave bearings. Renew all if so indicated.
• Ten year - strip motor, clean and examine stator bearings, renew bearings if so indicated

• Weekly (or every 4 lifts) - grease wire rope
• Semi-annually - visually inspect for wear, corrosion or damage
• Annually after two year service, annually remove one wire rope and test to destruction (Life expectancy for properly maintained wire rope is seven to ten years)
  

Rolls-Royce maintains a large field support staff of engineers. This staff is on call 24 hours a day, and ready to be dispatched to any Syncrolift^® installation, usually within 24 hours.

These engineers are available for training, retraining, inspection, repair, testing and start-up services. Each time we deliver a shiplift, we prepare a set of manuals that are unique to that Syncrolift installation. An identical copy of these manuals is maintained in Annapolis so that any question can be dealt with by people on two ends of a telephone or email, dealing with identical instructions. This often saves the need for a field trip.

Often it is necessary for a shipyard to dock an unusual vessel, one that does not match the exact limitations of the shiplift. It is very common for the shipyard to query our engineering department for an opinion or methodology to accommodate these odd vessels. We welcome such queries, and answers are provided quickly and completely.

Rolls-Royce maintains comprehensive records of every installation including detailed service records. We provide a complete spare parts and servicing function and will be pleased to quote on various levels of maintenance contracts. A planned maintenance service can be provided on request and a number of clients employ Rolls-Royce to undertake regular routine inspections.

Occasionally a customer requires assistance in selling an existing Syncrolift® shiplift, either because he is discontinuing operations or is planning a larger shiplift. We have provided this service several times.