0:00:02 > 0:00:06Stretching from Land's End to Dover,
0:00:06 > 0:00:08this is the busiest seaway in the world.
0:00:12 > 0:00:15And come hell or high water...
0:00:15 > 0:00:18Three, two, one. Fire it!
0:00:18 > 0:00:20No amount of training can ever prepare you
0:00:20 > 0:00:21for what we faced that night.
0:00:21 > 0:00:25..it's open for business 365 days a year.
0:00:25 > 0:00:28Over 90% of the world's trade travels by sea.
0:00:28 > 0:00:31It's not just TVs and refrigerators, it's everything around us.
0:00:31 > 0:00:34Teeming with every type of vessel...
0:00:34 > 0:00:36Everyone on board reckons their job is the hardest.
0:00:36 > 0:00:39..and a rich diversity of wildlife.
0:00:44 > 0:00:47It's kept safe by those who patrol its seaways.
0:00:47 > 0:00:49Just drag him onto the boat!
0:00:49 > 0:00:51Their actions standing between triumph...
0:00:51 > 0:00:53CHEERING
0:00:53 > 0:00:55..and disaster...
0:00:55 > 0:00:56Ease off. Ease off.
0:00:56 > 0:00:59..on the unpredictable waters of the English Channel.
0:01:05 > 0:01:07Today...
0:01:07 > 0:01:08'193 Falmouth Coastguard.'
0:01:08 > 0:01:11..the Royal Navy Air Squadron receive a distress call
0:01:11 > 0:01:13about trapped teenagers.
0:01:13 > 0:01:15'193, we're airborne at Culdrose.
0:01:15 > 0:01:19'We could be on scene in five minutes if you require immediate evacuation.'
0:01:19 > 0:01:23A new ferry captain takes the helm as the weather closes in.
0:01:23 > 0:01:25It's very challenging in the fog.
0:01:25 > 0:01:28Some of the nerve-racking bits are reduced visibility,
0:01:28 > 0:01:30manoeuvring the ship,
0:01:30 > 0:01:33sometimes you can't even see past the fo'c's'le which is only
0:01:33 > 0:01:3525 metres away.
0:01:35 > 0:01:37And in Southampton Dock...
0:01:37 > 0:01:40Yeah, we're just on our way to the ECH Park now.
0:01:40 > 0:01:43..engineers race to fix the port's giant forklifts...
0:01:47 > 0:01:49Just giving it a little hit where we'd free it up so it would start,
0:01:49 > 0:01:51but not in this case.
0:01:51 > 0:01:53..as a backlog of customers mounts up.
0:01:53 > 0:01:56You can see there is a bit of a queue starting to form.
0:02:04 > 0:02:08The bustling waters of the English Channel are full of every
0:02:08 > 0:02:10type of vessel imaginable.
0:02:10 > 0:02:14From giant cargo ships delivering all manner of goods to our shores,
0:02:14 > 0:02:17to pleasure boats simply messing about on the water.
0:02:21 > 0:02:24But perhaps the ones that are most familiar to many of us
0:02:24 > 0:02:25are the ferries.
0:02:25 > 0:02:27Top deck from seaways one.
0:02:27 > 0:02:31- 'Good morning.'- We're expecting about 180 tourists at the moment.
0:02:31 > 0:02:33No, my love, if you can go over onto the walkways, please.
0:02:33 > 0:02:38A staggering 3.4 million cars and 15 million people
0:02:38 > 0:02:41travel on these vessels every year to France and Europe.
0:02:41 > 0:02:43'Landing on. Happy?'
0:02:43 > 0:02:45Start beside. Out. 2P2.
0:02:45 > 0:02:49The quickest route is across the busiest shipping lane in the world,
0:02:49 > 0:02:51the Dover Straits.
0:02:51 > 0:02:54And all ferries crossing it run to very tight schedules
0:02:54 > 0:02:55with no room for error.
0:02:55 > 0:02:58The maximum draft and total number of persons on board?
0:02:59 > 0:03:03With so many high-value commercial vessels navigating
0:03:03 > 0:03:07just 21 miles of water from Dover to France, safety is paramount.
0:03:10 > 0:03:14Four-man BA team making an entry into the port alleyway
0:03:14 > 0:03:16aft end of deck seven.
0:03:16 > 0:03:20Last year we met chief officer on board the Delft Seaways,
0:03:20 > 0:03:22Mark Miller, as he put the ship's crew
0:03:22 > 0:03:26through their paces in a dramatic safety exercise.
0:03:26 > 0:03:28Dover Coastguard, Dover Coastguard.
0:03:28 > 0:03:31We have a fire on board. We require immediate assistance.
0:03:31 > 0:03:34These drills we do weekly. They're very important
0:03:34 > 0:03:38so that all the crew are fully trained in abandon ship procedures
0:03:38 > 0:03:41in order to facilitate if such an incident does occur.
0:03:44 > 0:03:47Since then, Mark's taken a step up the career ladder.
0:03:47 > 0:03:51It's my first week as captain, so no pressure.
0:03:51 > 0:03:53- Go into the middle.- All right.
0:03:54 > 0:03:55It's daunting.
0:03:55 > 0:03:59I'm responsible for the whole ship, the passengers and the crew.
0:03:59 > 0:04:02Every deck officer aspires to be a captain at some point
0:04:02 > 0:04:07during their career, and the buck stops here, basically.
0:04:07 > 0:04:11Captain Miller is in charge of the 35,000 tonne Delft Seaways,
0:04:11 > 0:04:14operating between Dover and Dunkirk.
0:04:14 > 0:04:16We all good to go, Mike? Full check sheet?
0:04:16 > 0:04:18We'll be coming off the berth,
0:04:18 > 0:04:21heading up towards the western entrance.
0:04:21 > 0:04:22It's a flood tide,
0:04:22 > 0:04:26so I'll start my turn a little bit earlier into the tidal with some
0:04:26 > 0:04:29extra power and we'll go through the middle of the western on the way out.
0:04:29 > 0:04:30- OK?- OK.
0:04:30 > 0:04:32He may be in charge now,
0:04:32 > 0:04:35but it's a far cry from where he began.
0:04:35 > 0:04:38I started off as a deck trainee, became an AB,
0:04:38 > 0:04:41became a quartermaster, became a junior officer,
0:04:41 > 0:04:45then became a first officer, chief officer and now a captain.
0:04:45 > 0:04:48It's taken me 24 years.
0:04:48 > 0:04:50Could have done it quicker.
0:04:50 > 0:04:52HE LAUGHS
0:04:52 > 0:04:55It may have taken him a while to become a captain.
0:04:55 > 0:04:56Hello, Steve, it's Mark.
0:04:56 > 0:04:59Can we start up and go standby two and two, please?
0:04:59 > 0:05:01But the sea is definitely in Mark's blood.
0:05:01 > 0:05:02Cheers, thanks.
0:05:04 > 0:05:05I come from a seafaring background.
0:05:05 > 0:05:08My dad was Royal Navy
0:05:08 > 0:05:11and there's no doubt in my mind he would be very proud of me.
0:05:14 > 0:05:18Having successfully made it out of Dover Port and into open sea,
0:05:18 > 0:05:21Captain Miller now faces weather conditions which even
0:05:21 > 0:05:24the most experienced of seafarers would struggle with.
0:05:24 > 0:05:26It's very challenging in the fog.
0:05:26 > 0:05:29Some of the nerve-racking bits are reduced visibility,
0:05:29 > 0:05:31manoeuvring the ship,
0:05:31 > 0:05:33sometimes you can't even see past the fo'c's'le
0:05:33 > 0:05:36which is only 25 metres away.
0:05:36 > 0:05:39Avoiding big ships in the fog is largely done
0:05:39 > 0:05:42by the bridge's radar systems.
0:05:42 > 0:05:45But smaller boats like pleasure yachts might not be picked up
0:05:45 > 0:05:46on the ship's instruments
0:05:46 > 0:05:49and the only way to spot them is the human eye.
0:05:49 > 0:05:51When we get down to two miles,
0:05:51 > 0:05:53we'll have two officers on the bridge.
0:05:53 > 0:05:57One will be myself and we'll have the officer of the watch.
0:05:57 > 0:06:00To add to the pressure, Captain Miller is in the middle
0:06:00 > 0:06:04of an ongoing assessment for a vital qualification.
0:06:04 > 0:06:06I've got a pilot on board with me today
0:06:06 > 0:06:10as I'm doing my Pilot Exemption Certificate for Dunkirk.
0:06:10 > 0:06:15So the pilots travel with me to make sure that I can pass my exams.
0:06:15 > 0:06:18It's standard practice for a harbour pilot to come on board
0:06:18 > 0:06:21and help steer large ships into port.
0:06:21 > 0:06:24But with these ferries making multiple channel crossings
0:06:24 > 0:06:28every day, it's not practical to have a pilot every time.
0:06:28 > 0:06:31What me doing this exam gives me is the exemption.
0:06:31 > 0:06:36I don't have to take a pilot, I am the pilot for that port.
0:06:36 > 0:06:39As well as the fog, Captain Miller's assessor, Patrice Ruyssen,
0:06:39 > 0:06:43is aware of some unusual tidal conditions which will make
0:06:43 > 0:06:47navigating into Dunkirk even more challenging today.
0:06:47 > 0:06:49We have an exceptionally high tide today.
0:06:49 > 0:06:54Since 18 years we know we don't have tides like this.
0:06:54 > 0:06:57So the current is very, very strong today.
0:06:57 > 0:07:01We are stressed because it's a very, very big ship for this kind of port.
0:07:04 > 0:07:08Captain Miller may be traversing the busiest area of the Channel...
0:07:09 > 0:07:11..but 700 miles away,
0:07:11 > 0:07:14where this stretch of water meets the Atlantic Ocean,
0:07:14 > 0:07:17the Royal Navy's 771 search and rescue squadron
0:07:17 > 0:07:20based in Cornwall face challenges of their own.
0:07:20 > 0:07:24Our location on the south-west peninsula requires us
0:07:24 > 0:07:27to operate in the Channel for the majority of our rescues.
0:07:27 > 0:07:31Lieutenant Commander Andy Watts knows only too well
0:07:31 > 0:07:34how unpredictable these waters can be.
0:07:34 > 0:07:36The harshness in the winter is fairly comparable
0:07:36 > 0:07:38to anywhere that the world may offer
0:07:38 > 0:07:41and therefore, to allow us to train in those conditions,
0:07:41 > 0:07:44makes sure we're best prepared when we then deploy.
0:07:45 > 0:07:47The crews operate 24/7
0:07:47 > 0:07:51and at any point in the day can be scrambled in 15 minutes flat.
0:07:52 > 0:07:56The Sea King helicopters they use were built in 1969.
0:07:57 > 0:08:00This is a Mark 5 Sea King, fairly long in the tooth
0:08:00 > 0:08:03and there's not many cars that you still drive 45 years old
0:08:03 > 0:08:05but still doing very well.
0:08:05 > 0:08:07RADIO CALL
0:08:07 > 0:08:09- 'Thank you.'- 'Where about?'
0:08:09 > 0:08:12'90 bug my side. Bug low your side, please.'
0:08:12 > 0:08:13'Bug low.'
0:08:13 > 0:08:15'Cabin crew, light, noise. Low my side.'
0:08:15 > 0:08:18'Testing.'
0:08:18 > 0:08:21Today the crew will be rendezvousing with a Penlee lifeboat
0:08:21 > 0:08:24down in the Channel for a winch exercise.
0:08:26 > 0:08:27'Roger, we're ready when you are.
0:08:27 > 0:08:31'If you can give us a course and speed when you are ready. Over.'
0:08:31 > 0:08:33'No visual with them anyway.'
0:08:33 > 0:08:35'Penlee, can you just confirm where you are?'
0:08:35 > 0:08:37'193 Penlee lifeboat.
0:08:37 > 0:08:40'We're approximately two miles west of Porthleven. Over.'
0:08:41 > 0:08:43'We're just north of you. We're closing now.
0:08:43 > 0:08:45'It should be just down now on the left-hand side.'
0:08:45 > 0:08:46'Yeah, got him.'
0:08:49 > 0:08:53We arranged with the Penlee lifeboats to do some essential training
0:08:53 > 0:08:55to transfer our old personnel
0:08:55 > 0:08:59and also to familiarise the crews from the lifeboat, because on many
0:08:59 > 0:09:03occasions we need to winch them up as well as any casualties.
0:09:04 > 0:09:06They plan to use the winch to put petty officer
0:09:06 > 0:09:09Mark Richardson down onto the deck.
0:09:10 > 0:09:13But first, as the observer, Andy needs to talk to the pilot
0:09:13 > 0:09:17to get the helicopter exactly in position above the lifeboat.
0:09:17 > 0:09:20'OK, just do a quick recce them. So you've got a solid boat,
0:09:20 > 0:09:21'nice angle at the moment.
0:09:22 > 0:09:24'One o'clock.
0:09:24 > 0:09:26'Got three sets of whip aerials.
0:09:26 > 0:09:30'At this height you are well clear of all obstructions.
0:09:30 > 0:09:31'Going out for him now.
0:09:31 > 0:09:34'Go on, dispatch. You're doing it nice and slow.
0:09:35 > 0:09:36'In the back.
0:09:36 > 0:09:38'Stay third of right. Two o'clock is your right.
0:09:38 > 0:09:40'You've got about 20 yards to the right.
0:09:41 > 0:09:43'It's at a good height. 18 yards.
0:09:43 > 0:09:45'15 yards. Good, light speed.
0:09:45 > 0:09:46'12 yards.
0:09:46 > 0:09:49'Ten. Eight yards.
0:09:49 > 0:09:50'Five yards.
0:09:50 > 0:09:53'Three yards. One.
0:09:53 > 0:09:55'Steady. And he's safely on the deck.
0:09:55 > 0:09:57'Safely on the deck. Working it strong.
0:09:57 > 0:10:00'Disconnect you and raise the winch until you're happy and visual.
0:10:00 > 0:10:03'Back and left, please.'
0:10:03 > 0:10:06Getting a man onto a moving boat from a moving helicopter
0:10:06 > 0:10:09is a tricky business and something they constantly practice.
0:10:09 > 0:10:13A lot of our calls, because of where we're located, is out to sea.
0:10:13 > 0:10:15It's very challenging
0:10:15 > 0:10:18and that's the essential part of going out every single day,
0:10:18 > 0:10:21training with a variety of different vessels,
0:10:21 > 0:10:26lifeboats, yachts, larger vessels, to ensure, when it's called for,
0:10:26 > 0:10:28in that dark night at 2.00 in the morning,
0:10:28 > 0:10:30180, 200 miles from coast,
0:10:30 > 0:10:34we can do it as quickly and effectively as possible.
0:10:35 > 0:10:38They may have successfully got Mark onto the deck of the boat
0:10:38 > 0:10:41but they're only halfway through the exercise
0:10:41 > 0:10:44and still need to get him safely back up to the Sea King.
0:10:44 > 0:10:46What goes down must come up.
0:10:46 > 0:10:49'On top. On top. Good position.
0:10:49 > 0:10:50'On top. Good position.
0:10:50 > 0:10:52'He's attached. Raise the winch, he's clear.
0:10:52 > 0:10:54'Go left to Lt. Clear left.
0:10:54 > 0:10:56'Can you back in left?
0:10:56 > 0:10:57'Get a bit of a swing.
0:10:57 > 0:11:00'Raise the winch. He's coming clear. Call when you're happy.
0:11:00 > 0:11:04- 'Happy visuals.- Roger. Just dampen out the swing.
0:11:04 > 0:11:05'Putting the cable out.'
0:11:12 > 0:11:16Mark is back on board and in the nick of time.
0:11:16 > 0:11:18Navy 193, Falmouth Coastguard. Over.
0:11:18 > 0:11:22Falmouth Coastguard have contacted the helicopter.
0:11:22 > 0:11:24Navy 193. We're airborne at Culdrose.
0:11:24 > 0:11:26We could be at the scene in five minutes
0:11:26 > 0:11:28if you require immediate evacuation.
0:11:28 > 0:11:31Falmouth Coastguard. Roger. Many thanks. Stand by.
0:11:31 > 0:11:33A member of the public has reported some
0:11:33 > 0:11:36people in trouble between the rocks and the sea.
0:11:36 > 0:11:38Update. So we've got two people cut off by tide.
0:11:38 > 0:11:40They're waving on the rocks.
0:11:40 > 0:11:43They've activated the lifeboat and the cliff rescue team
0:11:43 > 0:11:47and we're just proceeding until we get called for either tasking or
0:11:47 > 0:11:49we get told to wait.
0:11:49 > 0:11:51So we're in the right position at the right time.
0:11:51 > 0:11:53'Falmouth Coastguard. Roger.
0:11:53 > 0:11:57'We can confirm there are now persons now waving by the rock form.
0:11:57 > 0:12:00'Falmouth Coastguard, Navy 193. We're one minute from the area.
0:12:00 > 0:12:03'We'll remain on top until you call for our assistance.'
0:12:03 > 0:12:07Whilst we wait for Falmouth coastguards to decide
0:12:07 > 0:12:10whether we're required, we're just now making our way towards
0:12:10 > 0:12:14the scene so that if we're required, we're right ready to go.
0:12:19 > 0:12:22Search and rescue helicopters are just one of the ways
0:12:22 > 0:12:24the English Channel is kept safe.
0:12:25 > 0:12:29And as well as the RNLI, their activities are coordinated
0:12:29 > 0:12:32by the UK's Maritime and Coastguard Agency.
0:12:34 > 0:12:35All ships in the Dover Strait,
0:12:35 > 0:12:41this is Dover Coastguard information service broadcast at 1243 UTC.
0:12:41 > 0:12:44They're responsible for monitoring all vessels in the Channel.
0:12:44 > 0:12:46And do you have any dangerous cargo on board?
0:12:48 > 0:12:50Primarily, we're looking at vessels crossing the lane.
0:12:50 > 0:12:53We have a vessel here that is crossing the lane
0:12:53 > 0:12:57and he should cross at right angles to the flow of traffic.
0:12:57 > 0:12:59The reason for this is perspective to an oncoming vessel.
0:12:59 > 0:13:03It's easier for them to calculate whether there is a risk of collision.
0:13:03 > 0:13:07Obviously if we've got restricted visibility and at night-time,
0:13:07 > 0:13:12then it can be a higher risk to all those involved.
0:13:12 > 0:13:14In terms of search and rescue operations,
0:13:14 > 0:13:18their jurisdiction stretches 12 miles out into the sea.
0:13:20 > 0:13:23On the other side of the Channel, the French Coastguard look after
0:13:23 > 0:13:26the 12-mile limit that extends from their shores.
0:13:29 > 0:13:34Could you give me your last and next port and ETA, please?
0:13:34 > 0:13:40The UK and the France...and France have search and rescue agents
0:13:40 > 0:13:42which they're responsible for.
0:13:42 > 0:13:44The north, the UK search and rescue agents,
0:13:44 > 0:13:48and the south, the French search and rescue agent.
0:13:48 > 0:13:51We have to cooperate if necessary.
0:13:51 > 0:13:53Reading dispatch. Reading dispatch.
0:13:53 > 0:13:55The main thing is to discuss
0:13:55 > 0:13:58and to have some exchanges to make sure that we are not
0:13:58 > 0:14:02running the same operation at the same times in different ways.
0:14:04 > 0:14:05Like the UK Coastguard,
0:14:05 > 0:14:09the French often have to deal with unusual callouts.
0:14:09 > 0:14:12One time we found a kayak trying to cross
0:14:12 > 0:14:14to the Channel islands.
0:14:14 > 0:14:17It's far too long, but they don't know that.
0:14:17 > 0:14:22They are totally not aware of the situation, even the distance.
0:14:22 > 0:14:23It seems to be very close
0:14:23 > 0:14:28but in fact it's more than 15 or 20 nautical miles.
0:14:28 > 0:14:31As with their counterparts in Britain, the French Coastguard
0:14:31 > 0:14:35may have seen it all, but there's one thing they have little time for.
0:14:37 > 0:14:41Swimming the Channel is a uniquely British phenomenon.
0:14:41 > 0:14:42It's like a motorway,
0:14:42 > 0:14:46but in this motorway with a lot of lorries
0:14:46 > 0:14:48and the merchant vessels are the lorries.
0:14:49 > 0:14:50There is crossings.
0:14:50 > 0:14:54There are crossing buses, coaches, which are the ferries,
0:14:54 > 0:14:58and then you have some trawlers and you have some sailing vessels
0:14:58 > 0:15:01in summertime especially, but all the year long.
0:15:01 > 0:15:05You do not need really to have some swimmers in this area.
0:15:05 > 0:15:07HORN TOOTS
0:15:07 > 0:15:09CHEERING
0:15:09 > 0:15:12Nowadays, all those who wish to attempt swimming the Channel
0:15:12 > 0:15:15need to set off from the UK as France banned
0:15:15 > 0:15:19the practice of crossing from Calais to Dover 17 years ago.
0:15:20 > 0:15:25If really you want to swim a long time, you can go through a lake
0:15:25 > 0:15:28and go around the lake if you want.
0:15:31 > 0:15:35Crossing the Channel under your own steam from France may be a no-no,
0:15:35 > 0:15:38but when it comes to more legitimate Gallic exports,
0:15:38 > 0:15:41there's a good chance they'll arrive on our shores in Southampton.
0:15:43 > 0:15:46Every day thousands of containers will arrive here with
0:15:46 > 0:15:48goods from all over the world.
0:15:49 > 0:15:53The port is a major gateway to the rest of Britain for the imports
0:15:53 > 0:15:55we rely on for our day-to-day lives.
0:15:56 > 0:16:02Around 100,000 tonnes a day is moved from boat to lorry, rail or storage.
0:16:04 > 0:16:09The crane gets the imported goods off the ship and onto the quayside.
0:16:09 > 0:16:14The crane will discharge the container into lane one or three
0:16:14 > 0:16:15under the crane.
0:16:15 > 0:16:19The straddle carrier works underneath the crane.
0:16:19 > 0:16:23It picks a box up from the quay that's been delivered by the crane
0:16:23 > 0:16:28and takes it to the stack and stacks it.
0:16:30 > 0:16:32Whenever you go out shopping...
0:16:33 > 0:16:38..you will find produce that has come from containers that have
0:16:38 > 0:16:39come through the port of Southampton.
0:16:41 > 0:16:44But each valuable bit of lifting equipment must be maintained
0:16:44 > 0:16:46and fixed when it breaks down.
0:16:47 > 0:16:51Got Chris and Paul on breakdowns this morning.
0:16:51 > 0:16:55A small group of engineers is in charge of maintenance and repairs.
0:16:55 > 0:16:56Be safe out there.
0:16:56 > 0:17:00They have to do everything from fix a puncture on a giant tyre
0:17:00 > 0:17:03to reprogramming software on board.
0:17:03 > 0:17:07Chris Wells is one of the engineers in charge of the straddle carriers.
0:17:07 > 0:17:10My job here is to keep this fleet of
0:17:10 > 0:17:14straddle carriers that you see behind me running, really.
0:17:14 > 0:17:17But it's not just me, there is a huge team of engineers.
0:17:17 > 0:17:20We've got three shifts of about 16 blokes,
0:17:20 > 0:17:23so it's a really big team effort.
0:17:23 > 0:17:27The team from workshop 204 look after anything with wheels,
0:17:27 > 0:17:30and the straddle carriers have their own nickname.
0:17:30 > 0:17:31They're called vans here.
0:17:31 > 0:17:35It got to me when I first come here about nine years ago now.
0:17:35 > 0:17:38I couldn't understand why everyone was calling them vans
0:17:38 > 0:17:42but now it's just the way it is and that's the way it's stayed.
0:17:42 > 0:17:46They're big bits of kit, as you can see. No job is small on them.
0:17:46 > 0:17:48They are an exciting piece of kit to work on.
0:17:48 > 0:17:52Not a lot of people get to work on this type of kit.
0:17:52 > 0:17:56This is our main sort of information centre for down in the workshop.
0:17:57 > 0:18:00All the breakdowns that we have will come up on here.
0:18:00 > 0:18:02It's also got a really clever system
0:18:02 > 0:18:04where we can track a straddle carrier,
0:18:04 > 0:18:07so for example, I got called up on my radio
0:18:07 > 0:18:09that van 86 is coming back.
0:18:09 > 0:18:13I just want to know whereabouts it was so I know how long I've got
0:18:13 > 0:18:17and I can track him on a GPS that he's just about to round the corner
0:18:17 > 0:18:21into the yard and then I can pop up and see what's up with van 86.
0:18:24 > 0:18:28And in a matter of minutes, van 86 rolls around the corner to the
0:18:28 > 0:18:30workshop with an electrics problem.
0:18:31 > 0:18:35HE SHOUTS: Drive! Did you shut it down and start it back up again?
0:18:35 > 0:18:37Some repairs are easier than others.
0:18:39 > 0:18:42Easy breakdown that one. Some of them are, some of them aren't.
0:18:42 > 0:18:45For example, that one actually only needed a shutdown,
0:18:45 > 0:18:48which doesn't make us look that good, but...
0:18:49 > 0:18:52At least he's out working now earning money.
0:18:53 > 0:18:57A straddle carrier costs nearly three quarters of a million pounds
0:18:57 > 0:18:59and weighs 68 tonnes.
0:18:59 > 0:19:04It can carry almost its own weight - up to 50 tonnes at any one time.
0:19:06 > 0:19:09Each straddle carrier is as high as three double-decker buses.
0:19:09 > 0:19:13Back on the ground, the workshop engineers have been called
0:19:13 > 0:19:15out to a breakdown on the quayside.
0:19:15 > 0:19:19What's going on at the moment, we've got a carrier stuck out on the stack.
0:19:19 > 0:19:22So we actually need to go and attend this.
0:19:22 > 0:19:25So we can get him back here and then and work on him there because it's
0:19:25 > 0:19:27no good being stuck in the stack
0:19:27 > 0:19:29cos boxes may be needed out of that row.
0:19:31 > 0:19:35Like a roadside recovery firm, they have a set response time
0:19:35 > 0:19:38of just 15 minutes to get to the breakdown,
0:19:38 > 0:19:41and the quayside is a challenging place to negotiate.
0:19:41 > 0:19:43Our response time is now ticking,
0:19:43 > 0:19:46so we promise to be there within 15 minutes.
0:19:46 > 0:19:50Bit like the site's emergency services, really.
0:19:50 > 0:19:53'25 on ship at two lids, crane 25.'
0:19:53 > 0:19:56Driving along the quay, you've got to keep your wits about you
0:19:56 > 0:19:59because we've got cranes constantly working.
0:19:59 > 0:20:02They can be lifting containers off, could be lifting lids off,
0:20:02 > 0:20:04which are these big things there.
0:20:04 > 0:20:06And they're 50 tonnes each,
0:20:06 > 0:20:08so you don't want one of them dropped on your van.
0:20:08 > 0:20:11When Chris and his colleague Paul arrive,
0:20:11 > 0:20:14they can see the container's stuck under the straddle carrier.
0:20:14 > 0:20:16'Gate 20, mate.'
0:20:16 > 0:20:18Yeah, we're just attending van 88.
0:20:18 > 0:20:21Can I confirm isolations of rows either side, please?
0:20:21 > 0:20:24- Yes. All signed off, mate. - Cheers, mate.
0:20:25 > 0:20:28The container is badly dented.
0:20:28 > 0:20:31Due to the box being damaged, the machine can't lock onto it,
0:20:31 > 0:20:33so now we have to override the twist locks,
0:20:33 > 0:20:35get them unlocked and then we can hoist up,
0:20:35 > 0:20:37get the machine off the box then.
0:20:44 > 0:20:46Chris and Paul have to climb 15 metres to the
0:20:46 > 0:20:50top of the straddle carrier to get to the override switch.
0:20:50 > 0:20:55What we're doing here, we've got a special key that allows us
0:20:55 > 0:21:00to override the twist locks so we can get the machine unlocked...
0:21:03 > 0:21:05..and hopefully get off the van.
0:21:07 > 0:21:09With the engineers now in control,
0:21:09 > 0:21:11they can release the damaged container
0:21:11 > 0:21:14and the straddle carrier can get back to work.
0:21:17 > 0:21:21All right, that's that one sorted. I'll now hand that back to control.
0:21:21 > 0:21:23Ask them to move the barrier box.
0:21:23 > 0:21:25And we've already got our next job coming in,
0:21:25 > 0:21:26so we're off to that one now.
0:21:26 > 0:21:29PHONE RINGS 20 to control.
0:21:31 > 0:21:34Back in the workshop, the supervisors are used to dealing
0:21:34 > 0:21:36with emergency repairs.
0:21:36 > 0:21:38Breakdown is a breakdown, so it's the same as your car.
0:21:38 > 0:21:41You start it in the morning, you're expecting it to start.
0:21:41 > 0:21:43So, you know, and when it does start everything's fine,
0:21:43 > 0:21:45you go and do a journey,
0:21:45 > 0:21:49you get a puncture halfway along on your journey, whatever happens.
0:21:49 > 0:21:50So...
0:21:50 > 0:21:52that's what's happening here on a daily basis.
0:21:54 > 0:21:57We're all professional engineers.
0:21:57 > 0:21:59These machines are covered in electronics,
0:21:59 > 0:22:02heavy, mechanical, hydraulics.
0:22:02 > 0:22:05Every system is built into a mobile machine,
0:22:05 > 0:22:08so the lads aren't just specialists on one piece of equipment,
0:22:08 > 0:22:10they've got to know all systems.
0:22:12 > 0:22:16Outside, straddle carrier 45 has come in with a fault.
0:22:16 > 0:22:19Paul's first up the ladder to see what's wrong.
0:22:20 > 0:22:24I've just checked the water level, that's a little bit low.
0:22:24 > 0:22:27I just want to check the engine oil level now as well.
0:22:27 > 0:22:30See, I imagine that's probably low as well.
0:22:30 > 0:22:31Check the level.
0:22:31 > 0:22:33As you can see, that's the add mark and that's the full mark,
0:22:33 > 0:22:35so we're slightly low.
0:22:35 > 0:22:37We'll go around and top the level up to the full mark.
0:22:41 > 0:22:45There are sensitive electronics inside these cabinets.
0:22:45 > 0:22:48So when these machines go over the bumps all round the site,
0:22:48 > 0:22:51it can throw some of them out of it.
0:22:51 > 0:22:53So they just need to be checked over.
0:22:53 > 0:22:57Initially, all seems OK, but Paul has to get past an electronic
0:22:57 > 0:23:00control mechanism that's come from another part of Europe.
0:23:00 > 0:23:02Typical, this one's still in German.
0:23:02 > 0:23:04Is it? Now you've got to change the lingo?
0:23:04 > 0:23:06Got to try and change the language over.
0:23:06 > 0:23:08At the moment, and I'm just trying to look on the, erm...
0:23:08 > 0:23:10refuel pad and the fault history,
0:23:10 > 0:23:12but, erm, as I've come to it,
0:23:12 > 0:23:14this one's actually set in German at the moment,
0:23:14 > 0:23:15so I'm just checking my notes
0:23:15 > 0:23:18to find the correct parameter to change it to English
0:23:18 > 0:23:20so I can understand it a bit better.
0:23:20 > 0:23:24The engineers are problem-solving in almost all conditions.
0:23:24 > 0:23:26Gets about minus-five anyway,
0:23:26 > 0:23:29or...we've been up here in the snow before.
0:23:29 > 0:23:31Really got to wrap up then.
0:23:31 > 0:23:33If the wind conditions get up too high,
0:23:33 > 0:23:36we can't come up in, say, these cherry pickers.
0:23:36 > 0:23:39Er, and if the winds get too high,
0:23:39 > 0:23:43then the straddle carriers and the cranes aren't used,
0:23:43 > 0:23:45so then, we won't be going up them then.
0:23:45 > 0:23:48Paul puts the instructions back to English,
0:23:48 > 0:23:50and it's nearly ready to go.
0:23:50 > 0:23:52Paul's just tying up a few bits up there.
0:23:52 > 0:23:54He'll be down and that's when I'm going back to work.
0:23:56 > 0:23:57With everything working,
0:23:57 > 0:24:01straddle carrier 45 can get back on the quayside.
0:24:02 > 0:24:04But just when they think they're done...
0:24:04 > 0:24:06MESSAGE HEARD OVER RADIO
0:24:06 > 0:24:08..another machine's in trouble.
0:24:08 > 0:24:11The trucks waiting to be unloaded are backing up,
0:24:11 > 0:24:13and it's down to Chris to respond.
0:24:13 > 0:24:16We're being, er, sent here, there and everywhere
0:24:16 > 0:24:17trying to find a machine.
0:24:25 > 0:24:27On board the ferry Delft Seaways,
0:24:27 > 0:24:31Mark Miller is making one of his first Channel crossings
0:24:31 > 0:24:32as a new captain.
0:24:35 > 0:24:36So far on this trip,
0:24:36 > 0:24:39he's faced unusually high tides and fog,
0:24:39 > 0:24:43all while being assessed by a steely-eyed French harbour pilot.
0:24:45 > 0:24:50It's standard practice for pilots to help steer large ships into port.
0:24:50 > 0:24:54But if Captain Miller can get a Pilot Exemption Certificate,
0:24:54 > 0:24:57his skills will be all the more valuable to the ferry operator.
0:24:57 > 0:24:59Four knots by the end...
0:24:59 > 0:25:01slowing all the time for the berth.
0:25:01 > 0:25:04Erm, the wind, at the moment, about six knots off the berth.
0:25:04 > 0:25:05- Happy?- Happy.
0:25:05 > 0:25:08In the last few hours, Captain Miller's safely overcome
0:25:08 > 0:25:11some of the Channel's most challenging conditions,
0:25:11 > 0:25:14but now he faces one of the biggest tests for a new captain,
0:25:14 > 0:25:17safely docking his 35,000 tonne ship
0:25:17 > 0:25:20in the narrow ferry port at Dunkirk.
0:25:20 > 0:25:21I'll take the steering.
0:25:23 > 0:25:24Got it, thank you.
0:25:29 > 0:25:32It's always the captain's responsibility
0:25:32 > 0:25:34to bring the ship to a safe stop.
0:25:34 > 0:25:37A mistake at this crucial stage in the voyage
0:25:37 > 0:25:40could jeopardise Mark's new position as captain.
0:25:48 > 0:25:50I've got a point down here,
0:25:50 > 0:25:52if you look on the, on the belting,
0:25:52 > 0:25:55that lines up with the position mark ashore.
0:25:55 > 0:25:58So I have a rough estimate of where we're going to stop.
0:25:58 > 0:26:02Um, it does change slightly with tides.
0:26:02 > 0:26:03He may be the man in charge,
0:26:03 > 0:26:06but he has to rely heavily on his crew.
0:26:06 > 0:26:07Heading?
0:26:07 > 0:26:10Heading is... 71.
0:26:12 > 0:26:13I can't concentrate on everything,
0:26:13 > 0:26:16so there's a man up forward counting is in,
0:26:16 > 0:26:17I've Joe backing me up,
0:26:17 > 0:26:20reminding me of what the wind's doing, the speeds,
0:26:20 > 0:26:21how the ship's reacting.
0:26:21 > 0:26:24And then I concentrate on doing everything
0:26:24 > 0:26:26as slowly, gently and safely as possible.
0:26:27 > 0:26:29You've always got to be focused.
0:26:29 > 0:26:30At the end of the day,
0:26:30 > 0:26:34you've got to land a very large ship
0:26:34 > 0:26:35that weighs a lot,
0:26:35 > 0:26:39that's got a lot of momentum with it, so therefore, you've, you know,
0:26:39 > 0:26:41you've got to land it as softly as possible.
0:26:41 > 0:26:45Um, not just for the ship's sake, but for everybody on board.
0:26:45 > 0:26:47And the idea of the game is
0:26:47 > 0:26:50that you make everybody's passage as comfortable as possible.
0:26:56 > 0:26:57Around about a metre off.
0:27:01 > 0:27:04Probably about four metres or so from the second part.
0:27:04 > 0:27:05A quarter of a knot.
0:27:07 > 0:27:10- Landing on.- OK, mate, fast, please.
0:27:10 > 0:27:13OK, Delft Seaways, four and a half. Weigh fast, weigh fast, all and out.
0:27:13 > 0:27:15It's been a challenging crossing,
0:27:15 > 0:27:18but the ship is now safely dockside.
0:27:18 > 0:27:21- OK, very good, Captain. - Thank you very much, thank you.
0:27:21 > 0:27:24And local pilot Patrice seems suitably impressed.
0:27:24 > 0:27:28I think that he will be a good captain for the company
0:27:28 > 0:27:32and you have a good management on the bridge.
0:27:32 > 0:27:34They're a very good team,
0:27:34 > 0:27:38so he has no problem with this kind of ship and this kind of crew.
0:27:38 > 0:27:40To be honest with you,
0:27:40 > 0:27:42that, I thought, was heavy landing for me.
0:27:43 > 0:27:45Um, I'll be completely honest.
0:27:45 > 0:27:48I'm normally, I'm normally a little bit gentler.
0:27:48 > 0:27:51The mood may be light up on the bridge for now...
0:27:53 > 0:27:55..but nine decks below in the engine room,
0:27:55 > 0:27:57things aren't quite so smooth.
0:27:57 > 0:28:01TELEPHONE RINGS
0:28:01 > 0:28:03- Hello, bridge. Captain speaking. - Hi, Captain.
0:28:03 > 0:28:05Yeah, we've got a problem with main engine number two.
0:28:05 > 0:28:07We need to change an injector
0:28:07 > 0:28:11erm, so, er, if it's OK with you, we'll disable the engine.
0:28:11 > 0:28:12How long will it take?
0:28:12 > 0:28:14It should be back in within an hour.
0:28:14 > 0:28:16That'll be brilliant, OK.
0:28:16 > 0:28:19- All right, thank you. Cheers.- Cheers, bye.
0:28:19 > 0:28:20Dan, we've got permission from the old man.
0:28:20 > 0:28:23We've got to change injector number seven
0:28:23 > 0:28:24on main engine number two.
0:28:24 > 0:28:27- All right?- OK. - We'll get the engine shut down.
0:28:27 > 0:28:29The fuel injector ensures
0:28:29 > 0:28:32that the diesel is distributed as evenly as possible
0:28:32 > 0:28:34around the engine cylinders.
0:28:34 > 0:28:37It's one of a diesel engine's most complex components.
0:28:37 > 0:28:39Do you think you'll be able to manage it?
0:28:39 > 0:28:41- Yeah, I'll be able to.- All right.
0:28:41 > 0:28:42Let's go on out.
0:28:42 > 0:28:46For apprentice engineer Dan, this will be a first.
0:28:46 > 0:28:47I've always been into mechanics.
0:28:47 > 0:28:49Like, my dad's a mechanic.
0:28:49 > 0:28:52I've been around cars and bikes my whole life.
0:28:52 > 0:28:55Hey, Leszek, can you come and give Dan a hand
0:28:55 > 0:28:58with this injector change on main engine number two.
0:28:59 > 0:29:01Coming from car engines that are small,
0:29:01 > 0:29:02you lean over them,
0:29:02 > 0:29:04where as this is taller than me, so...
0:29:04 > 0:29:06It's a lot different, yeah.
0:29:06 > 0:29:08Take charge of the job.
0:29:08 > 0:29:10Leszek's here to assist you.
0:29:10 > 0:29:13And, er...all the best.
0:29:15 > 0:29:17A ship this size has four engines,
0:29:17 > 0:29:19but can function with just two.
0:29:19 > 0:29:22However, it's vital that all are in good working order
0:29:22 > 0:29:24in case of any emergencies.
0:29:24 > 0:29:28So this is a big responsibility for Dan.
0:29:28 > 0:29:31I've let him have a go at doing this one in charge him self.
0:29:31 > 0:29:35So he'll call the shots, he'll make all the decisions.
0:29:35 > 0:29:37Erm, he's got a good hour and a half to do the job,
0:29:37 > 0:29:41so hopefully, he should make it in time.
0:29:41 > 0:29:45This ferry is due to head back into the Channel soon,
0:29:45 > 0:29:46and these repairs need to be done
0:29:46 > 0:29:49well before final manoeuvres into Dover.
0:29:54 > 0:29:57It's imperative that any craft heading out into the sea
0:29:57 > 0:30:00is well maintained. And those that aren't
0:30:00 > 0:30:03can often find themselves encountering the emergency services.
0:30:06 > 0:30:10Down in Cornwall, 771 Squadron Sea King helicopter
0:30:10 > 0:30:12has been out on a vital training mission.
0:30:12 > 0:30:14We've done training today with the winch,
0:30:14 > 0:30:16so, in terms of me operating it
0:30:16 > 0:30:18and Mark going down as a winch man.
0:30:18 > 0:30:19We're all familiar,
0:30:19 > 0:30:21we've done some winching with that also.
0:30:21 > 0:30:23So the right-hand seat pilot
0:30:23 > 0:30:27and everybody's familiar with the procedure that we would employ.
0:30:27 > 0:30:29But just as they're completing the operation,
0:30:29 > 0:30:33an emergency call out comes in from Falmouth.
0:30:33 > 0:30:35INDISTINGUISHABLE RADIO REPORT
0:30:35 > 0:30:37Sending them to investigate reports
0:30:37 > 0:30:42that a group of youngsters are stranded on coastal rocks.
0:30:42 > 0:30:44Navy 193, we're airborne at Culdrose.
0:30:44 > 0:30:48We can be on scene in five minutes if you require immediate evacuation.
0:30:48 > 0:30:51Falmouth Coastguard, Roger, many thanks, stand by.
0:30:51 > 0:30:56Quick to respond, the 771 Squadron's helicopter soon arrives.
0:30:57 > 0:30:59- Can you see them?- Yeah, visual.
0:30:59 > 0:31:01All right, we'll just check they're the ones.
0:31:03 > 0:31:06The visual. Yeah, so they're about 300 yards from the beach.
0:31:08 > 0:31:12We've three survivors in wet suits, teenage boys.
0:31:12 > 0:31:16Er, we are ready to lift them off.
0:31:16 > 0:31:18They do a lot of coasteering along here, don't they?
0:31:18 > 0:31:21- They are definitely in trouble, are they?- Yeah, I think so.
0:31:21 > 0:31:24Roger. Well, we'll lift them anyway. We've got a call.
0:31:24 > 0:31:26Andy decides to put petty officer
0:31:26 > 0:31:30Mark down on a nearby rock to assess the situation.
0:31:31 > 0:31:34And we are ready to back for the one drop-off.
0:31:34 > 0:31:37OK, ready in the back, permission for the winch and outboard.
0:31:37 > 0:31:39OK, ready on the backboard
0:31:39 > 0:31:42and right in your two o'clock about 35 yards.
0:31:46 > 0:31:4730 feet of cable out.
0:31:47 > 0:31:49Third and right, your two o'clock, 30 yards.
0:31:51 > 0:31:53Border right. Right and forward.
0:31:53 > 0:31:55This is rescue 193, over.
0:31:55 > 0:31:57Right only three o'clock, 20 yards.
0:31:58 > 0:32:00Bringing the Sea King close into the cliffs
0:32:00 > 0:32:02is an exacting operation.
0:32:03 > 0:32:06Back and right, half past three, 12.
0:32:07 > 0:32:08Ten yards.
0:32:08 > 0:32:10Up and over the rocky area, eight.
0:32:12 > 0:32:14Back and right, half past three.
0:32:14 > 0:32:16Three yards.
0:32:16 > 0:32:18Four o clock, two, one.
0:32:18 > 0:32:20Steady, steady.
0:32:20 > 0:32:21Safely on the rocks.
0:32:25 > 0:32:28The noise of the Sea King's rotor blades can be a distraction,
0:32:28 > 0:32:31so the helicopter pulls away.
0:32:33 > 0:32:35I think they're giving us that they're OK.
0:32:35 > 0:32:38So I'll just check and make sure there's nobody else.
0:32:38 > 0:32:42Nobody else further along this rocky section.
0:32:42 > 0:32:44He's coming across now, one of them, to him.
0:32:48 > 0:32:50It turns out they're simply traversing
0:32:50 > 0:32:53the tidal areas of the rocks for fun,
0:32:53 > 0:32:54which is known as coasteering,
0:32:54 > 0:32:56and don't need assistance.
0:32:59 > 0:33:01Mark is winched back on board.
0:33:01 > 0:33:04The lifeboat and cliff rescue team are stood down.
0:33:13 > 0:33:16The I winched down and they gave me the OK sign.
0:33:16 > 0:33:18So, straight away, I knew they were all right.
0:33:18 > 0:33:21They were wearing wet suits, they were wearing boots and gloves,
0:33:21 > 0:33:23so I knew obviously, they weren't hypothermic,
0:33:23 > 0:33:25they weren't trapped, they weren't cold.
0:33:25 > 0:33:26Being a local boy myself,
0:33:26 > 0:33:30I know they do a lot of coasteering along that side of Maenporth.
0:33:30 > 0:33:32So when I initially seen them, I thought it was probably the case.
0:33:32 > 0:33:35A local or a local tourist, probably a tourist,
0:33:35 > 0:33:37not from around here
0:33:37 > 0:33:40has called with good intentions and, but...
0:33:40 > 0:33:43this is what we're here for, this is our job.
0:33:43 > 0:33:45Better to be safe than sorry.
0:33:45 > 0:33:49All callouts have to be investigated in case of emergency.
0:33:49 > 0:33:51And for this helicopter team from Culdrose,
0:33:51 > 0:33:55a day of winch training has been put immediately to good use.
0:33:55 > 0:33:57The reason these guys do what they do.
0:33:57 > 0:34:01- I feel amazing. - CREW LAUGHS
0:34:01 > 0:34:02I feel like the Lynx advert.
0:34:02 > 0:34:05CREW LAUGHS
0:34:05 > 0:34:07Yeah, you see, every job is different
0:34:07 > 0:34:09and we keep our spirits up
0:34:09 > 0:34:13with a little bit of, er, good, er, cooperation back there
0:34:13 > 0:34:15and chat after the job.
0:34:15 > 0:34:17Just to make sure that no-one's head's a bit too big.
0:34:19 > 0:34:23Time to head back to base and wait for the next callout.
0:34:29 > 0:34:33200 miles away in the busy port of Southampton,
0:34:33 > 0:34:36engineers Chris and Paul are still hard at work.
0:34:36 > 0:34:40Yeah, we're just on our way to the ECH Park now.
0:34:40 > 0:34:41They've been called out to
0:34:41 > 0:34:45a broken-down empty container handler, or ECH.
0:34:45 > 0:34:48It is essentially like a giant forklift, yes.
0:34:48 > 0:34:50Capable of lifting nine tonnes.
0:34:50 > 0:34:54ECHs are essential to the smooth running of the port.
0:34:54 > 0:34:57As you can see, there is a bit of a queue starting to form.
0:34:59 > 0:35:02Today, with the trucks waiting to load and off-load containers
0:35:02 > 0:35:04starting back up...
0:35:04 > 0:35:07- We'll have two cut through there, won't we? Give them a...- Yeah.
0:35:07 > 0:35:10..it's vital any breakdowns are fixed as soon as possible.
0:35:12 > 0:35:16It's been reported to Chris that the ECH has broken down and won't start.
0:35:17 > 0:35:21But he won't know what the problem is until he investigates further.
0:35:21 > 0:35:23Want to give it a tap?
0:35:23 > 0:35:25Chris thinks he knows what it might be,
0:35:25 > 0:35:30and he's opted to use a particularly sophisticated piece of equipment.
0:35:35 > 0:35:40While Chris works on the engine, Paul tries to fire it up.
0:35:40 > 0:35:43HE HAMMERS
0:35:43 > 0:35:45Just try plugging the van in.
0:35:45 > 0:35:47Sometimes the starter motor will get stuck,
0:35:47 > 0:35:50and just giving it a little hit will free it up so it will start,
0:35:50 > 0:35:52but not in this case.
0:35:52 > 0:35:55It could possibly be a slightly flat battery,
0:35:55 > 0:35:57so just doing a basic jump-start,
0:35:57 > 0:35:59a bit like what happens on a car.
0:35:59 > 0:36:02Er, we've got extra batteries on our van
0:36:02 > 0:36:04that we plug into these machines.
0:36:04 > 0:36:06Give them a bit of a jump when they need it.
0:36:06 > 0:36:08Good?
0:36:08 > 0:36:09Yeah, hang on.
0:36:10 > 0:36:12ENGINE STARTS
0:36:14 > 0:36:16Success.
0:36:17 > 0:36:18With the engine started...
0:36:18 > 0:36:21Is there anywhere you want this ECH 16 put?
0:36:21 > 0:36:23..time for Paul to get this empty container handler
0:36:23 > 0:36:25to where it needs to be.
0:36:34 > 0:36:36You don't know what you're going to face.
0:36:36 > 0:36:37I just take every day as it comes,
0:36:37 > 0:36:41and all days are different here, which is nice.
0:36:41 > 0:36:44And you won't really get the same day again and again.
0:36:45 > 0:36:48It's why, personally, I couldn't work in an office.
0:36:49 > 0:36:51Chris may be suited to his job,
0:36:51 > 0:36:53but by the time he gets back to the workshop,
0:36:53 > 0:36:56true to form, there's another problem.
0:36:56 > 0:36:57Just had another call.
0:36:57 > 0:37:01ECH 23, which is an empty container handler, forklift, er...
0:37:01 > 0:37:03They're gagging for machines over there.
0:37:03 > 0:37:05There's a bit of a queue of lorries.
0:37:05 > 0:37:07So we better go over and get ECH 23 going.
0:37:10 > 0:37:12Yeah, 20.
0:37:12 > 0:37:15MAN ON RADIO: Yeah, the driver 75 has already set off on the next route.
0:37:15 > 0:37:17There's only eight ECHs.
0:37:17 > 0:37:20Not all of them are working all at the same time,
0:37:20 > 0:37:22cos we have maintenance on them, et cetera.
0:37:22 > 0:37:25So, usually, we only have about five or six working,
0:37:25 > 0:37:28and obviously, it can soon get chocked up like this,
0:37:28 > 0:37:30cos they can only take one container off a lorry at a time.
0:37:33 > 0:37:38The job they're attending was reported as a faulty transmission.
0:37:38 > 0:37:40An intermittent fault, like with one of these machines,
0:37:40 > 0:37:41is a nightmare to track,
0:37:41 > 0:37:44because there are so many individual systems on it,
0:37:44 > 0:37:46but sometimes we get over here
0:37:46 > 0:37:48and there's no fault found, so...
0:37:48 > 0:37:50Unfortunately, we have to wait until
0:37:50 > 0:37:52the fault comes up again and stays there,
0:37:52 > 0:37:53so that we can find it and fix it.
0:37:55 > 0:37:56Going over some rough ground, so...
0:37:58 > 0:38:02Despite the gears on this giant forklift now seeming to work,
0:38:02 > 0:38:04Chris must make sure it's fully operational
0:38:04 > 0:38:07before he can declare it ready for service.
0:38:08 > 0:38:09There we go, that's max out.
0:38:09 > 0:38:13And then, it can do a spread of functions up there,
0:38:13 > 0:38:14like side shift of the box.
0:38:17 > 0:38:19And then, er, get it into place.
0:38:20 > 0:38:22She's good, I've given her a test drive,
0:38:22 > 0:38:24I've tested all the functions.
0:38:24 > 0:38:26Er, she goes forward and reverse...
0:38:28 > 0:38:30..and she hoists all the way to the top.
0:38:30 > 0:38:32So, as far as I'm concerned with this machine,
0:38:32 > 0:38:33it can go back to work.
0:38:35 > 0:38:37With the empty container handler good to go,
0:38:37 > 0:38:39it can now join forces with the others
0:38:39 > 0:38:42and help clear the backlog of trucks.
0:38:42 > 0:38:44PERSON ON RADIO: 20.
0:38:44 > 0:38:47ECH 23 available in the yard.
0:38:48 > 0:38:52Thank you very much. We need that one.
0:38:52 > 0:38:54Yeah, I noticed.
0:38:54 > 0:38:55Ha.
0:38:58 > 0:39:02The movement of containers around the port may be back up to speed...
0:39:02 > 0:39:05but still no time for a cuppa.
0:39:05 > 0:39:07Chris has routine maintenance to get on with.
0:39:12 > 0:39:13Is that what they use in Formula One?
0:39:13 > 0:39:16Not quite this robust, I don't think.
0:39:16 > 0:39:18I think theirs is a bit more special,
0:39:18 > 0:39:19more expensive than this one.
0:39:20 > 0:39:24Changing a tyre on the family car is a familiar job to some,
0:39:24 > 0:39:27but replacing one capable of supporting 50 tonnes
0:39:27 > 0:39:29takes a bit longer.
0:39:29 > 0:39:3012 wheel nuts altogether,
0:39:30 > 0:39:33so...they don't come off quickly.
0:39:33 > 0:39:36Not Formula One speeds here.
0:39:36 > 0:39:38Well, I use this trolley, first of all, to get it off,
0:39:38 > 0:39:42and then, once it's on the trolley, I can then use a forklift,
0:39:42 > 0:39:44go and put this over in the tyre bay
0:39:44 > 0:39:46and get a new tyre back over.
0:39:53 > 0:39:54Yeah.
0:39:56 > 0:39:58Just doing this so when I pull it back,
0:39:58 > 0:40:00it don't fall off the trolley and injure anyone.
0:40:00 > 0:40:03Cos they're pretty hefty weight tyres.
0:40:03 > 0:40:05These tyres don't come cheap,
0:40:05 > 0:40:08and if this one hasn't fully reached the end of its life,
0:40:08 > 0:40:10it'll be remoulded and put back on the vehicle.
0:40:10 > 0:40:12Each tyre has its own number,
0:40:12 > 0:40:15so we can't track where it is on the site,
0:40:15 > 0:40:17like what machine it's been put to,
0:40:17 > 0:40:19cos these are £2,000 apiece.
0:40:20 > 0:40:21Right, in you come, straight.
0:40:23 > 0:40:25Straight on. OK, hold it there.
0:40:29 > 0:40:30OK. Down you go, mate.
0:40:38 > 0:40:41It's been a long day for mechanical engineer Chris,
0:40:41 > 0:40:44but at least it's the end of his week-long shift,
0:40:44 > 0:40:47and he's earned a well-deserved rest.
0:40:47 > 0:40:50This place will still be here in two days when I come back.
0:40:50 > 0:40:51So, not long off.
0:40:51 > 0:40:54And then, er...back to it and to do it all again.
0:41:02 > 0:41:05As day turns into night on the English Channel,
0:41:05 > 0:41:08not everyone's finished their shift.
0:41:08 > 0:41:10On board the Delft Seaways,
0:41:10 > 0:41:14newly-appointed captain Mark Miller is still hard at work...
0:41:14 > 0:41:17as he approaches Dover in darkness.
0:41:20 > 0:41:24Below decks, apprentice engineer Dan was earlier instructed
0:41:24 > 0:41:25to change a fuel injector
0:41:25 > 0:41:29in one of the ship's four massive diesel engines.
0:41:29 > 0:41:33It's the first time he's ever tackled this complex job,
0:41:33 > 0:41:37but Dan was told he must do it within an hour and a half.
0:41:37 > 0:41:41It's a challenging job in cramped, hot and noisy conditions.
0:41:42 > 0:41:46But in the nick of time, Dan manages to make this vital repair.
0:41:47 > 0:41:50But until chief engineer Steve tests the engine,
0:41:50 > 0:41:54they won't actually know if Dan's really fixed it.
0:41:54 > 0:41:56Hopefully, if he's done his job right,
0:41:56 > 0:41:57it'll start up first time.
0:42:02 > 0:42:04In the noise of the engine room,
0:42:04 > 0:42:07a thumbs up indicates it's all gone to plan.
0:42:07 > 0:42:09MACHINE BEEPS
0:42:10 > 0:42:12- That all looks good, Ash.- Good.
0:42:12 > 0:42:14Just going to let the captain know
0:42:14 > 0:42:16that his engine's ready for arrival.
0:42:16 > 0:42:19Erm...I'm sure he'll be pleased, so...
0:42:20 > 0:42:21Bridge are just going to give him a call.
0:42:21 > 0:42:24- TELEPHONE RINGS - Here he is now.
0:42:24 > 0:42:26Control room, Steve speaking.
0:42:26 > 0:42:27Hi, Captain.
0:42:27 > 0:42:29Yeah, that's main engine two injector change complete,
0:42:29 > 0:42:32er...tested. Everything looks good.
0:42:33 > 0:42:34Thank you. Bye.
0:42:36 > 0:42:38So, job's done. Well done, Dan.
0:42:38 > 0:42:40Captain's happy, so...
0:42:40 > 0:42:41..well done.
0:42:43 > 0:42:44And back on the bridge,
0:42:44 > 0:42:48Captain Miller has a special celebration to attend.
0:42:48 > 0:42:51The plan is tonight, um, go and have a dinner.
0:42:51 > 0:42:55It's a celebration dinner for just commencing being a captain.
0:42:56 > 0:42:59- And you're late for your own dinner? - I'm afraid I am.
0:42:59 > 0:43:01Somebody had to work and nobody offered.
0:43:01 > 0:43:04HE LAUGHS
0:43:04 > 0:43:07Choosing a life at sea involves many sacrifices,
0:43:07 > 0:43:10but it's the hard work and dedication
0:43:10 > 0:43:12of all those who traverse these waters
0:43:12 > 0:43:15that keeps the English Channel moving.