Number 173 Hydrex offers turnkey maintenance and repair solutions for the offshore industry Ecospeed applied on several fast-going ferries, enabling optimum hull performance during entire service life Hydrex active with jobs around the world Long lay-up periods have no effect on quality of Ecospeed coating www.shiphullperformance.org: a new informational website launched by Hydrex An interview with Stijn Janssens, Hydrex Technical Services Officer
EASY AND EFFECTIVE UNDERWATER HULL CLEANING AROUND THE WORLD Throughout the years Hydrex has invested in the development of underwater hull cleaning equipment and now offers an international service that can give ships back their efficiency. This quick and effective service is offered on a worldwide basis through a network of underwater hull cleaning stations strategically located around the planet. All Hydrex underwater hull cleaning units are carefully constructed to minimize the occurrence of damage on the underlying paint layers while still removing all types of fouling. This restores a vessel s performance as close to its optimum condition as possible and offers ship owners a considerably saving in fuel. All Hydrex offices and service stations are equipped with multiple sets of these hull cleaning units which can be mobilized rapidly to any port. All divers are trained to achieve the fastest possible cleaning rates without losing the high quality Hydrex is known for. 2
Table of contents Hydrex offers turnkey maintenance and repair solutions for the offshore industry 5-8 Ecospeed applied on several fast-going ferries, enabling optimum hull performance during entire service life 9-13 R. de Visser Hydrex active with jobs around the world 16-20 Long lay-up periods have no effect on quality of Ecospeed coating 22 www.shiphullperformance.org: a new informational website launched by Hydrex 23 An interview with Stijn Janssens, Hydrex Technical Services Officer 25-26 3
Message from Hydrex founder Boud van Rompay The first feature article in this magazine is a very good illustration of these maintenance services. In it you can read about the cleaning and inspection work performed by Hydrex on three drilling vessels located in the Gulf of Mexico. Hydrex has a wide range of maintenance and repair services available for the shipping and offshore industries. These services can entail simple repair or maintenance work as well as comprehensive on-site repair services and project management. For these complex operations Hydrex can offer turnkey solutions that are tailor-made to fit you and your vessel s need. All projects are engineered and carried out in close cooperation with the customer, from the design and construction of equipment all the way through to the actual repair or replacement and follow-up afterwards. The maintenance services offered to the offshore industry include the removal of fouling from offshore units to reduce weight, increase the available deck capacity and facilitate any needed visual inspection or non-destructive testing. These inspections are carried out by our certified diver/technicians and allow owners to be in total control of their unit s hull condition. The second feature article discusses the many benefits Ecospeed gives to ship owners and specifically to owners of fast going vessels with a fixed route. The article also gives several examples of ferries that have recently been coated with Ecospeed, including the largest Ro-Pax ferry in the world. Further in this magazine you can read about some of the operations that were recently carried out by Hydrex diver/technician teams around the world. We end the magazine with an interview with Stijn Janssens, one of the Hydrex Technical Services Officers. Stijn is responsible for coordinating the repair and survey programs with the Indian Navy as well all other operations carried out by our offices in India. We hope you enjoy reading this magazine and are looking forward to hearing your feedback on it. Best regards, Boud van Rompay Hydrex has certified divers at its disposal, ready to perform all types of offshore inspections. ISO 9001 certified To receive a free copy, fax to: Hydrex N.V. +32 3 213 53 21 or e-mail to hydrex@hydrex.be 4
Hydrex offers turnkey maintenance and repair solutions for the offshore industry In the second half of 2010 Hydrex carried out a full inspection and removed all fouling from three drilling vessels in the Gulf of Mexico owned by Transocean, the world s largest offshore drilling company. This was done to reduce the weight and drag of the vessels and increase their available deck load. Fully equipped and operational, all Hydrex offices are ready to mobilize immediately to carry out high quality and fast underwater cleaning operations or any other maintenance and repair work on offshore units and ships located in fields. By taking advantage of a range of underwater cleaning units designed in-house specifically for offshore operations all types of fouling can be removed from any type of offshore Hydrex is fully equipped to service all types of offshore units. Even thick layers of hard marine growth of more than 10 inches can be removed by Hydrex cleaning. If required a special reclaim system can be added to the equipment to prevent the fouling from spreading in the environment. structure. An all-embracing combination of single, twin and triple head cleaning machines is used. The twin head MC212 unit is designed for cleaning light, medium and heavy marine fouling from tubular pipes, bracings and legs of offshore oil and gas platforms, jetties, piles, intakes and ship hulls. The triple head MC312 Typhoon machine is easily adaptable to the shape of a ship or pontoon hull. Its heads self-adjust to the contours of the hull making complex areas far easier to clean. Even thick layers of hard marine growth of more than Thick layers of marine growth can easily be removed with the Hydrex underwater cleaning units. 10 inches can be removed by Hydrex cleaning. If required a special reclaim system can be added to the equipment to prevent the removed fouling from spreading in the environment. By removing all fouling from an offshore unit its weight is reduced and the available deck capacity is increased. A cleaning operation also facilitates any needed visual inspection or non-destructive testing. This allows owners to be in total control of their unit s hull condition. Hydrex also offers considered preventive and protective maintenance services that are highly effective and save a great deal of time and money in comparison to the costs incurred during a breakdown for which there has been no preparation. With preventive engineering and scheduled maintenance, work delays can be eliminated or reduced significantly. 5
Underwater maintenance work performed on drillships in the Gulf of Mexico For the maintenance operation in the Gulf of Mexico, an inspection team and two cleaning teams were mobilized from the Hydrex offices. In-house developed ship hull cleaning equipment used on drilling vessel. Hydrex had carried out repairs on other offshore units belonging to the same owner and he knew that the company could offer the required services without having to take the vessels to drydock. We ve known Transocean for a very long time, says Hydrex Senior Project Manager René Huybregts. We first met during projects carried out on a big offshore repair yard in The Netherlands some years ago. We stayed in touch ever since, assisting them with the design and procedure for installing specific types of cofferdams and performing other repair work. Impressed by the complete package of both engineering and project management that Hydrex offers, the owner then asked Hydrex to perform the inspection and cleaning of one of their drilling vessels in the Gulf of Mexico. Satisfied with the way the operation was handled, a second and third drilling vessel were soon added. The scope of work consisted of a comprehensive UWILD inspection of the three vessels, and an inspection of the weld seams in particular, and a cleaning of the underwater parts of the units. Replacement of anodes was also performed wherever needed and all overboard lines were blanked in order to enable inspection from the inside. The Hydrex teams also assisted with the removal of one of the vessels thrusters so that they could be overhauled. Underwater hull cleaning of drillship in Gulf of Mexico. While a surveyor was monitoring the team that was carrying out the inspection required by the classification society, an underwater cleaning team was working simultaneously to make sure that the operation would be Flexibility is a very important factor during a large operation like this. Hydrex teams are trained to adapt themselves to the customer s program as much as possible instead of the other way around. finished within the available timeframe. For the same reason, one of the teams was transferred to the second vessel to begin the second operation while the other teams finished the underwater cleaning work on the first unit. Hydrex diver during underwater hull cleaning on offshore unit. The vessels were away from the field and because the crew also needed to carry out other maintenance and repair work on the vessels a very tight schedule had to be followed. This schedule allowed the team to plan the inspection and cleaning operation around the other work. Flexibility is a very important factor during a large operation like this. Hydrex teams are trained to adapt themselves to the customer s program as much as possible instead of the other way around. 6
Azimuth thruster being lifted out of the water to be overhauled. Drillship serviced by Hydrex in Gulf of Mexico. We have gotten very good feedback from the customer, says René. The way we handled a big operation like this was highly appreciated. This is very important for us. The customer needs to be satisfied with the result. We work very hard to keep improving our services to make sure that we can work out the best possible solution for any problem that a customer might be faced with. On-site repair services and full project management for offshore/support units Besides tailor-made maintenance operations such as the one described above, Hydrex also has the know-how and expertise to provide comprehensive on-site repair services and project management for offshore related units. These projects are engineered and carried out by Hydrex in close cooperation with the customer. Starting from the design and construction of equipment all the way through to the actual repair or replacement and subsequent follow-up. Hydrex also has the know-how and expertise to provide comprehensive on-site repair services and project management for offshore related units. These projects are engineered and carried out by Hydrex in close cooperation with the customer. CLASS ACCEPTED UNDERWATER STERN TUBE SEAL REPAIRS UNDER WARRANTY Using our flexible mobdock method to create a dry underwater environment, we have carried out stern tube seal repairs and replacements underwater for some years now in cooperation with top specialist suppliers. This technology brings drydock conditions to the ship rather than having to take the ship to drydock, saving a considerable amount of time and money in doing so. cargo or other commercial operations in port. Visit the special stern tube seal repair section on our website for more information and examples of the many seal repairs we have performed in recent years. This class accepted method is performed by our diving teams under our warranty. It can be used while the ship is carrying out its usual Phone: +32 3 213 5300 (24/7) Fax: +32 3 213 53 21 hydrex@hydrex.be www.hydrex.be 7
way through to the repair or replacement. If a problem occurs the Hydrex technical department can take the project out the customer s hands and find the most viable solution. Within a very short timeframe Hydrex diver/technicians can be on site solving the problem. Hydrex diver-technicians securing wires to pad eyes on azimuth thruster. Our technical department and diving teams are trained to carry out exact procedures and deliver a professional product or service while minimizing off-hire time yet maintaining high quality. All Hydrex diver/technicians are also fully certified and can be mobilized immediately. A good example One possible action that can be taken is to install a permanent thruster repair and replacement system. This system has been developed so it can be tailored to most vessels. It can be included in the planning for a newbuild, installed on a unit going to drydock or constructed and brought onboard at any other suitable time. With such a system on standby, any repair work to the thruster that may arise can be dealt with much more quickly and easily. Using cofferdams allows for a wide range of repairs to be performed while normal operations at sea are maintained. These turn-key projects are planned and managed by Hydrex in close cooperation with the customer. It includes formulation of safety guidelines, writing working procedures, design and construction of cofferdams and any other necessary equipment all the of this is the recent emergency inspection and insert job on a semi-submersible vessel that was carried out in Malaysia in only five days. A fast response such as that can save precious time for customers in the case of an emergency or tight deadline. Hydrex also offer a wide range of possible repair services that make use of specially designed cofferdams. These can be rigid or flexible depending on the type of repair. Going to drydock is often not a feasible option for offshore related units because of the down time, loss of production and subsequent financial setback this brings about. Using cofferdams allows for a wide range of repairs to be performed while normal operations at sea are maintained. Hull, thruster, seal and spud can repairs are some of the most common underwater repairs made possible by the external cofferdam technology. Mobdock lifted from the pontoon and lowered into the water. 8
Ecospeed applied on several fast-going ferries, enabling optimum hull performance during entire service life Over the last couple of months several owners of fixed route passenger vessels have chosen Ecospeed as the preferred coating to protect their vessel s underwater hull for its entire sailing life. Among the vessels coated with Ecospeed are the largest Ro-Pax ferry in the world, a newbuild ferry in Croatia, and one of the vessels that provides ferry services across the Delaware Bay on the East Coast of the United States. These vessels will all benefit greatly from the fuel optimizing possibilities Ecospeed offers, as well as the coating s lasting protection against damage from cavitation and ice. After assembly of a newbuild vessel the weld seams are coated, finishing the application. The initial application of the Ecospeed underwater hull coating can easily be geared to the schedule of the yard. This flexibility can be achieved with Ecospeed because the coating has versatile application potentials. of the two required layers can be applied at any time during the building process, even when there is a winter period or serious bad weather between applications. Ecospeed applied on bulbous bow of largest RO-PAX ferry in the world. Under normal operation, ferries have to drydock once a year to comply with classification regulations. During the busy tourist season these ferries need to be sailing to make money so the best time for drydocking is the low season when there are fewer passengers. For this reason the majority of these ferries come into drydock for a short time during the winter months. This presents the owner with bad weather conditions in which to perform repair work to the paint system, and often therefore a quality paint job cannot be assured. For these reasons, it is essential to reduce the necessary maintenance and paint work in drydock. The initial application of the Ecospeed underwater hull coating can easily be geared to the schedule of the yard. This flexibility can be achieved with Ecospeed because the coating has versatile application potentials. Either The durability of Ecospeed also makes the planning of future drydockings far easier for the shipowner and the shipyard. No repainting beyond minor touch-ups will be required. These touch-ups can easily be done during a short drydock visit. Enhancing the performance of the complete underwater hull The short drydocking times give ferry operators little opportunity to take all the hull maintenance steps needed to reduce fuel consumption. The use of Ecospeed on the hulls, however, opens the door to looking deeper into how to optimize their fuel efficiency in 9
Ecospeed flexible overcoat time allows for easy application during the block phase. between dockings. Ferries sail on a fixed route, so the ports they visit and the turnaround time is known in advance. Knowing the exact schedule makes it possible to implement a stricter underwater maintenance program. Hydrex can help ferry operators with this by monitoring the condition of the ship hull through detailed in-water inspections. Based upon these findings a tailor-made maintenance program can be set up. This, combined with Ecospeed s performance-enhancing benefits, enables ferry owners to optimize the hulls and thus the fuel efficiency of their vessels. The smoothness attained by the coating provides best hydrodynamic conditions for the vessel to operate at maximum efficiency. Increased fuel costs are caused by the added resistance characteristics of each coating system that is a consequence of the marine fouling that accumulates on the underwater hull. Towing tank experiments have made it possible to estimate the inherent added drag levels. The rate of increase over time is estimated roughly from data available in scientific literature. Ecospeed's resistance decreases over time, unlike that of other coatings. Regular underwater treatment of Ecospeed is used as a performance enhancement measure. This keeps added drag caused by marine fouling Regular underwater treatment of Ecospeed will improve the coating s surface texture and hence increase its hydrodynamic efficiency. under control. Moreover, this treatment improves the coating s surface texture and hence its hydrodynamic efficiency. As a result, by adjusting the treatment interval, the increased fuel costs are minimized to HYDREX OFFICE FULLY OPERATIONAL AT THE STRAIT OF GIBRALTAR Our Hydrex office in Algeciras, Spain offers a large variety of maintenance programs and repair works for ship owners and the offshore industry, both underwater and above water. Underwater maintenance services include hull cleanings, propeller polishings, class accepted surveys and tail-shaft wear down readings. Underwater repair work consists of propeller repairs, shell plating crack repairs, mobdock repairs, rudder pintle repairs and any type of welding work. Hydrex Spain also offers a wide range of above water operations including accomodation ladder repairs, anchor and chain work, cell guide repairs, crane repairs, hatch cover repairs and mechanical and engine works. Hydrex Spain is fully geared to carry out repairs at anchorage and in port. All operations are Hydrex Spain Poligono Industrial Palmones II Calle Dragaminas Nave N29 11370 Algeciras Spain certified by the classification societies and are carried out by highly qualified divers and technicians all of which have extensive experience. Phone: +34 956 675 049 (24/7) Fax: +34 956 921 914 E-mail: info@hydrex.es 10
mentioned EU-LIFE demonstration project to provide scientific data and to authenticate the non-toxicity of the Ecospeed hull performance technology. This research proved that the coating is 100% toxin-free and that there is no negative effect on the water quality or the marine environment at network consisting of 18 ferry routes in Scandinavia and around the UK. After a stringent study of the Ecospeed ship hull performance technology, Stena Line opted for a full Ecospeed maintenance contract, consisting of preparation and coating Application of Ecospeed on bottom plating of Delaware Bay ferry. significantly lower levels than would be the case for an SPC or foul release paint. Ecospeed properties prevent fouling penetration, making the cleaning process extremely easy. It can be performed underwater or with high pressure tools in drydock and can be repeated whenever needed during the vessel s lifespan without causing any damage or deterioration to the coating. The coating s surface characteristics even improve significantly with each hull cleaning. This unique quality enables shipowners to have their ship s hull restored to its optimum condition whenever needed. This allows them to have their vessel operational again without the enormous expense of repainting. Because of the pulsed release of biocides or an increased risk of transferring non-invasive species (NIS), a number of the ports frequented by ferries do not authorize in-water hull cleaning. After the submission of the experimental results of an EU-LIFE demonstration project to port authorities and environmental agencies worldwide, several economically important ports have already overturned the ban on underwater hull cleaning specifically for vessels coated with Ecospeed. Ecospeed is completely non-toxic In 2008, stringent tests were carried out within the framework of the afore- Research proved that Ecospeed is 100% toxin-free and that there is no negative effect on the water quality or the marine environment at any point of its application, sailing or maintenance. any point of its application, sailing or maintenance. This is important for ferry operators who have reduced impact on the environmental high on their agenda. Applying Ecospeed allows them to sail with a completely non-toxic hull coating system. Some cases in point World s largest Ro-Pax ferry sailing with Ecospeed With a length of 240 meters and combined passenger and freight capacity of 230 cars, 300 freight vehicles and 1,200 passengers, MV Stena Britannica was launched in October 2010. Owner Stena Line is one of the world s largest ferry companies with a fleet of 35 modern vessels and Europe s most comprehensive of the underwater hull and routine maintenance to keep it in optimum condition. The first step in this maintenance program was the in-water conditioning of the underwater hull. This conditioning was carried out with specially designed tools and brought the smoothness of the coating s surface to an optimum condition by aligning the glass platelets inside the vinyl ester matrix. This will allow for an improvement of Ecospeed s surface characteristics with each further hull cleaning throughout the service life of the vessel. Stena Line actively works to avoid damage to the marine and land environment. Whenever new operations are being planned or when new technology is being implemented, the R. de Visser Ecospeed s non-toxicity fits perfectly with Stena Line s ecological beliefs. 11
Ecospeed is also ideal for thruster tunnel protection. environmental consequences are evaluated to minimize the company s ecological footprint. Designed to have a low environmental impact, Stena Britannica is built in line with Stena Line's Energy Savings Program. Ecofriendly features include catalytic converters, an improved hull design, highly efficient engines and better combustion rates, all helping to reduce environmental impact. Ecospeed fits in perfectly with these objectives. The coating is 100% environmentally safe, contributes greatly to reduced fuel consumption and therefore GHG emissions, and thus fits perfectly with Stena Line s own ecological beliefs. The vessel, which sails between Harwich and Hook of Holland, was built at two different locations in Germany, Warnemunde and Wismar. An Ecospeed application is very easy and can easily be adapted to the building schedule. The application was finished after the blocks were assembled in Wismar, in time for the vessel s delivery. Ecospeed protecting underwater hull of Delaware Bay ferry In early 2011 the underwater hull one of the three 98 meter ferries crossing Delaware Bay from Cape May to Lewes was coated with Ecospeed at the Colonna Shipyard in Norfolk, Virginia. With Ecospeed the vessel will not have to be repainted. Regular maintenance will keep the performance of the vessel stable at its optimum level, resulting in significant savings in fuel. MV Delaware is owned by the Delaware River and Bay Authority (DRBA) and was one of the original three vessels of the company s 1970s fleet. Her sister ships are the MV Cape May and MV Twin Capes; the The two stern thrusters of newbuild ferry in Croatia were also coated with Ecospeed. latter is also scheduled to be coated with Ecospeed. Ice class 1A ferry to sail safely on Canadian South-East coast with Ecospeed At the end of 2010, Ecospeed was applied to the 95 meter newbuild ferry Bella Desgagnés at the Kraljevica Shipyard in Croatia. The entire application, including surface preparation with grit blasting and application of both layers of Ecospeed, was carried out in only five days. The vessel is set to replace MV Nordik Express which is due for retirement, after sailing round trips between Rimouski and the Strait of Belle Isle on the East Coast of Canada since 1987. Unlike Nordik Express, which lays up each winter, the ice class 1A The second decisive factor was the economic benefits that can be obtained through the use of the hull coating system. With Ecospeed the vessel will not have to be repainted, saving the cost of repainting and the additional drydock time required. Regular maintenance will keep the performance of the vessel stable at its optimum level, resulting in significant savings in fuel. Cape May ferry in Norfolk, Virginia, after surface preparation. 12
have seen on other vessels, we will have a product that we really wanted on this vessel and on other upcoming new constructions. Conclusion: Restoring the performance of the hull by repainting it can be time-consuming and therefore expensive in drydock. However, once Ecospeed has been applied, this is no longer the case. Instead, ferry operators can optimize the hull performance, and thereby fuel consumption, by inwater maintenance which can be done economically outside of drydock. Newbuild ferry at shipyard in Croatia. Bella Desgagnés will also operate year-round and has been designed for a high ice capability. Ecospeed s going north, says Mr. Rossi, Vice President and General Manager of Engineering and Operations with Despite the frequent impact of large pieces of floating dry ice, none of the vessels sailing with Ecospeed in icy conditions have required more than just a few touch ups during their drydock visits. resistance against ice is ideal to complement the vessel s structural ice protection. For over four years, several vessels coated with Ecospeed have been sailing the most northern parts of the Baltic Sea during the winter season when they are almost completely frozen. Despite the frequent impact of large pieces of floating dry ice, none of these vessels have required more than just a few touch-ups during their drydock visits. The evidence these dockings gave of Ecospeed s durability and protection against harsh winter conditions convinced the owners of Bella Desgagnés that the coating was ideal for their newbuild ferry. We have been looking for a better paint to be applied to our vessels, especially for the vessel Transport Desgagnés Inc. Bella Desgagnés will operate in first year ice through the winter. If the coating performs in the same manner as we Ecospeed is applied in only two coats, making the coating process faster than other paint systems. Newbuild ferry in Croatia after application of second coat of Ecospeed. 13
Worldwide network 14
of service stations 15
Hydrex active with jobs around the world Propeller modifications in France, Italy and the Netherlands Over the last month Hydrex diver/technician teams performed several propeller modifications on container vessels in ports in Europe. These operations were performed to restore the propellers balance and bring their performance back as close to their optimum performance as possible after the propeller blades had suffered damage due to cavitation or collisions with ice or debris. Propeller blade modification in Italy In Gioia Tauro, Italy, a Hydrex team straightened four damaged blades of the propeller of a 265 meter vessel and cropped the remaining two. The team used the in-house developed cold straightening machine to bring the bent blades back to their original shape. For the cropping they used the measurements taken during a detailed inspection to calculate the most economical cutting line that would Even severely bent blades can often be restored to their original form with the Hydrex cold straightening equipment. make sure that the propeller s balance would be restored. Propeller blade cropping in Belgium Close to the Hydrex headquarters in Antwerp two blades of the propeller of a 210 meter vessel were cropped in Rotterdam, the Netherlands, because the blades had bent too much to be straightened. To make a full assessment of the damage, the team first performed an underwater inspection. The information acquired was then used to calculate and determine the correct measurements needed to modify the trailing edges of the propeller blades. The two blades were then cropped and all edges on the cropped areas were grinded and polished. Crack repair on propeller blades in France When a 200 meter vessel suffered cavitation and other damage to its propeller a Hydrex diver/technician team traveled to Le Havre, France, to perform the required modifications to the damaged blades of a two hundred meter container vessel. The team ground out the cracks on two of the propeller s blades and cropped the cracked area on a third propeller blade. Next all rough edges were Damage on one of the propeller blades of a container vessel in Le Havre. Cropping propeller blades is done after detailed measurements and calculations. polished to make sure that no further cavitation damage would occur. The diver/technicians worked in shifts to perform the repair as fast as possible to make sure that the vessel did not lose any unnecessary time. 16
Underwater stern tube seal replacement in Zeebrugge At the end of January 2011, a Hydrex diver/technician team replaced the stern tube seals of a RoRo vessel that was suffering an oil leak. The team carried out the operation underwater using the special Hydrex flexible mobdock technique during the vessel s stay in Zeebrugge, Belgium. The team created a dry working environment underwater by installing the flexible mobdock around the stern tube seal assembly. This allowed them to remove the old seals and replace them with new ones. The team rotated in shifts to make sure that the replacement would be finished as soon as possible to allow the customer to keep to the sailing schedule of the vessel. For the same reason the ship needed to shift to another berth during the operation. Because of the flexibility of the Hydrex team members this could be done without interfering with the repair operation. FULLY OPERATIONAL IN NORTH AMERICA Hydrex US is prepared to mobilize immediately and is capable of efficiently servicing offshore units and ships calling ports in Canada, North, Central and South America as well as the Caribbean. The Hydrex team worked around the clock to make sure that the operation was finished as fast as possible. Saving significant amounts of time, trouble and expense through its on-site work, Hydrex services range from a complete review of a vessel s external condition all the way through to highly technical major repairs or replacements of a ship s external underwater equipment and machinery. Repairs to thrusters, propellers, rudders, stern tube seals, damaged or corroded hulls and all other underwater services are done by professional teams trained and qualified to carry out complex technical tasks underwater while the vessel is in-situ. l major classification societies. Hydrex US 604 Druid Rd, Clearwater, FL 33756 The stern tube seals were replaced underwater inside the flexible mobdock, avoiding a costly visit to drydock. Phone: +1 727 443-3900 (24/7) Fax: +1 727 443 3990 info@hydrex.us www.hydrex.us 17
Rudder alignment in Mobile, Alabama In February Hydrex performed an inspection and realignment of the rudder of a 245 meter tanker while the vessel was afloat in Mobile, Alabama, U.S.A. A Hydrex diver/technician team mobilized from the office in Clearwater to assist the vessel during stops in Fairground in the Gulf of Mexico and Mobile and correct the alignment of its rudder. After the team carried out both an internal and external inspection of the rudder it was confirmed that it was not in its normal pitch position and needed to be realigned. No other damage was found on the rudder so that no further repairs were necessary. Because the team needed additional diving and hydraulic equipment to perform the operation, the decision was made to move the vessel to Hydrex certified welders preparing the rudder for repairs. Mobile, Alabama At this location the team first positioned two barges with all their equipment next to the rudder, after which they started the operation. HYDREX OFFICES IN INDIA READY TO MOBILIZE Hydrex has two fully staffed offices in India. One in Mumbai and one on Visakhapatnam, covering the East and the West Coast of India. Equipped with a complete array of Hydrex diving and repair equipment, both offices are ready to carry out any necessary repair and maintenance work and provide preventive as well as problem solving services. All operations will be carried out by professional Hydrex teams, trained and qualified to perform complex technical tasks underwater. All procedures are fully approved by all major classification societies. Hydrex Mumbai Phone/Fax: +91 222 2046 988 (24/7) E-mail: mumbai@hydrex.be Hydrex Vishakhapatnam Phone/Fax: +91 891 2711 863 (24/7) E-mail: vishakhapatnam@hydrex.be With the assistance of the vessel s mooring lines and several slings the team secured the rudder. Using special hydraulic equipment, the team was able to detach the rudder from the vessel and align it correctly, in close Two teams working simultaneously during the securing of the rudder after its realignment. communication with a representative of the manufacturer. During the operation the team worked in shifts around the clock. Extra welders were also mobilized to secure to the rudder again after the alignment. This was done to finish the operation as soon as possible and avoid any additional loss of time for the customer. 18
IN-SITU BOW THRUSTER OPERATIONS The Hydrex lightweight flexible mobdocks are designed to be easily transported around the world and are used to close off the thruster tunnel on both sides, allowing divers to perform repairs and other operations in a dry environment around the bow thruster unit. This technique enables them to reinstall the propeller blades of an overhauled thruster inside the thruster tunnel after the unit has been secured or replace the blades or seals and perform repair work on a specific part without removing the unit. Since the development of this flexible mobdock technique, numerous thruster repairs have been carried out by Hydrex diver-technicians around the world. There is no need to send the vessel to drydock as all operations can be carried out in port or while the vessel is stationary at sea. Normal commercial activities can therefore continue without disruption. Recently a Hydrex diver/technician team mobilized to Cochin, India to perform a full inspection of the three bottom hinges of a dock gate. Weighing 500 tons and with a width of 47.5 meters and a height of 11.4 meters, the thirty-year old gate is scheduled to be replaced. In order to make the removal of the old gate and the installation of the new one as smooth as possible, Hydrex was asked to make a detailed assessment of the condition of the three bottom hinges of the current gate. The team therefore carried out thickness measurements of the plate material of the hinges of the gate and of the eyes that keep the locking pins in place. Phone: + 32 3 213 5300 (24/7) Fax: + 32 3 213 5321 hydrex@hydrex.be www.hydrex.be Underwater inspection of bottom hinges of dock gate in India This provided the customer with all the necessary information to prepare the replacement. The bottom hinges of this 47.50 meter wide dock door were inspected to make a full assessment of their condition. 19
Underwater inspection of oil terminal in Al-Mu ajiz In February 2011, a team of Hydrex diver/technicians performed inspection work on some sixty legs of an oil terminal located in Yanbu, just north of Al-Mu ajiz in Saudi Arabia. The facility had been closed since the start of the first Gulf War and is planned to be put back into operation twenty years later after a full refit. Hydrex has certified divers at its disposal, ready to perform all types of offshore inspections. HYDREX WEST AFRICA IN PORT GENTIL, GABON Hydrex West Africa is situated in Port Gentil, Gabon right next to Cape Lopez Bay. Working closely together with the headquarters in Antwerp the office can benefit from Hydrex s long tradition in the ship repair and offshore industry. Port Gentil is a general and bulk cargo port. It is the only port on the Gabon coast with a bunkering service. The sheltered bay is ideally suited for in-water work. This combined with its central location on the African West coast makes it the ideal place to have repair or maintenance work carried out on a ship, barge or rig in optimal circumstances. The inspection of the legs allowed the customer to make a detailed assessment of their condition. For this reason Hydrex was asked to carry out an inspection of the legs of the terminal. The team also performed the necessary measurements to allow for a full assessment of the underwater part of the workstation. Hydrex West Africa can mobilize teams immediately to service vessels and offshore units in Port Gentil or any other suitable location in West Africa. A good example of this is the recent removal, repair and reinstallation of a 40 ton swing-up azimuth thruster of an offshore crane barge that was servicing rigs in an oil field off the coast of Gabon. The entire operation was performed while the unit stayed at anchorage just outside the oil field. The scope of the work consisted of an inspection of the weld seams, a close visual inspection, thickness measurements, cathodic protection measurements and an inspection of the general condition of the construction. The Hydrex team consisted of CSWIP certified divers who carried out the Hydrex diver prior to inspection of oil terminal in Saudi Arabia. inspection to a depth of thirty meters to the highest quality and safety standards. Hydrex West Africa Sis TLC/ Cité Shell BP 2160 Port Gentil - Gabon Phone : +241 04 16 49 48 (24/7) E-mail: westafrica@hydrex.be 20
SHIP HULL PERFORMANCE TECHNOLOGY Ecospeed ship hull performance technology lasts the lifetime of the vessel. The need for full repaints during future drydockings is eliminated. An impermeable and extremely tough coating is combined with an underwater cleaning system keeping the hull roughness at an optimum level and resulting in a major saving in fuel. a Ecospeed is a 100% non-toxic technology and is guaranteed for 10 years. Its surface texture will improve over time with regular inwater hull maintenance. Phone: +32 3 213 5318 Fax: +32 3 213 5321 info@ecospeed.be www.ecospeed.be 21
Long lay-up periods have no effect on quality of Ecospeed coating As a consequence of the current economic climate, more and more ship owners are forced to lay one or more of their ships up for longer periods. This has, however, no adverse effect on an Ecospeed coating which can always be restored to its optimum condition, regardless of how much fouling has attached itself to the hull while the vessel has been laying idle. Ecospeed is ideally suited for ships during lay-ups because of its impermeability. This gives the coating its excellent and durable anticorrosive properties and protects the underwater hull against damage caused by any type of marine fouling. Despite the aggressive nature of certain types of fouling, no rust or damage to the steel will be present on the underwater hull of the vessel after cleaning. This is illustrated by a cruise ship that remained stationary in the Caribbean for seven months after it was coated with Ecospeed. After this period the coating s qualities allowed a complete removal of all fouling from the underwater hull of the vessel during an underwater cleaning without causing Even after long stationary periods the underwater hull of a vessel coated with Ecospeed can easily be cleaned underwater. any damage to the underlying paint layers. The coating's properties totally prevent fouling penetration, making the cleaning process extremely easy. It can be performed underwater or with controlled high pressure tools in drydock and can be repeated whenever needed during the vessel s lifespan without causing damage or deterioration in quality. The coating s surface characteristics even significantly improve with each underwater hull cleaning. This unique quality gives ship owners the opportunity to have Ecospeed is ideally suited for ships during lay-ups because of its impermeability. This protects the underwater hull against damage caused by any type of marine fouling. their ship operational again and its hull restored to its optimum condition whenever needed without any additional financial setback. Thick layer of fouling on cruise ship after laying idle in the Caribbean for seven months. Fouling removal from cruise ship without damage to the Ecospeed coating. 22
www.shiphullperformance.org: a new informational website launched by Hydrex Anew website, www.shiphullperformance.org has just been launched by Hydrex. Its purpose is to help inform shipowners, operators, charterers, naval architects, government officials and any other decision makers with an interest in getting the best performance out of ships and fleets while reducing the environmental footprint of their vessels. The new website contains all the new Hydrex White Papers and Journal ready for free download. Visitors only need to register once and can then log in any time and search, read and download Hydrex White Papers and Journals and other material as it is added. The website also contains useful references organized by subject, news items, pertinent links to related websites, a glossary of terms related to ship hull performance and an offer for a free vessel or fleet assessment. The website is live and available right now. Simply go to www.shiphullperformance.org, register and start browsing and downloading material. The White Papers and Journals can be downloaded free of charge. Members can choose whether or not to receive new White Papers and Journals automatically as these are published and if so, whether they want electronic or printed versions or both. We welcome comments and contributions. Simply email editors@ shiphullperformance.org and we will respond. In future we aim to add material from experts in the field of ship hull performance presented in a manner which can be easily assimilated by the non-scientific community. The information can be used to make correct decisions regarding budgetary, economic and environmental aspects of managing vessels, fleets, ports and the marine environment. The right decision can save a company or a navy millions of dollars every year. The informed decision is a right decision. You are invited to visit www.shiphullperformance.org now and to register if you feel the information and news would be of value. 23
Worldwide network of offices and service stations Underwater solutions avoid drydocking Offshore repair and maintenance services Fully trained and certified diver/technicians Ship hull cleaning equipment designed specifically for offshore operations Fast response centers with instant mobilizable equipment Turnkey underwater solutions for the offshore industry Phone: +32 3 213 5300 (24/7) Fax: +32 3 213 5321 E-mail: hydrex@hydrex.be www.hydrex.be 24
Hydrex s expansion into the Indian market An interview with Stijn Janssens, Hydrex Technical Services Officer In 2009 the Directory of Naval Architecture (DNA) of the Indian Ministry of Defense chose Hydrex as its exclusive provider in a repair and survey program. This program enables the Indian Navy to keep its fleet operational at all times and achieve large savings in doing so. Since then Hydrex has opened two offices in India; one in Vishakhapatnam and one in Mumbai, allowing us to service customers in all of India and large parts of Asia. We talked to Stijn Janssens who is coordinating the survey and repair programs as well as all other activities of the two offices. Stijn has had ten years of underwater repair and maintenance experience before joining Hydrex Technical Services. Hydrex: Can you briefly tell us how you got involved with Hydrex? Stijn Janssens: After I graduated I started working as a technician. Soon I realized that this was not what I wanted to do so I started working for a ship repair company that also builds new vessels, located close to the Hydrex headquarters. After about five years I switched jobs and started working for a diving company Stijn Janssens, Hydrex Technical Services Officer. kid and I developed my love for shipping when I was very young. As a diver I did inspections, blanking and repairs for that company, but on a much smaller scale than Hydrex does. After five years I had no more opportunities to grow with this company and I applied for a job with Hydrex where I started as third diver and climbed the ranks to first diver. Due to medical reasons I was not allowed to dive any more as of last year. Hydrex then gave me the opportunity to join Technical Services, for which I am very grateful. As a diver, Hydrex had already given me the chance to evolve tremendously, As a diver, Hydrex had already given me the chance to evolve tremendously, but when I couldn t dive any more they gave me the option to continue my career with the company but in a different direction. have been able to develop a different aspect of my career. H: The Indian Navy project then came under your supervision, as well as the offices in Mumbai and Vishakhapatnam, right? SJ: That is correct. Our contract with the Indian Navy was signed in the same period so I was part of it from the very start. Soon after the start of the program, Hydrex opened two offices in India to be able to service customers outside of our contract as well. I coordinated the establishment of these offices; making sure that all logistics were taken care of, getting equipment on the new locations, arranging apartments for the staff members of the offices, establishing partnerships and relationships and getting visas. Both offices are fully operational. The Hydrex staff members in India arrange the mobilization of equipment, and contact any required local support for an operation. They also handle the local paperwork and write the job reports. Everything is then sent to me and I gather everything and make sure that the administrative part is complete. This is important because the Hydrex group has six offices on four different continents and everything needs to be brought together in because I wanted to do something with my passion for shipping. I was always attracted to water and everything to do with water. I have also been in the Sea Scouts when I was a but when I couldn t dive any more they gave me the option to continue my career with the company but in a different direction. This has helped me in that difficult period. Since then I Mumbai Visakhapatnam Hydrex has two offices in India ready to mobilize immediately. 25
Stijn meeting with the Indian Minister of Defense and a delegation of the Indian Navy at Techyard 2010. an overview of the entire group. For this reason all the administration needs to be completed according to the same procedures. H: How is the relationship with the Indian Navy? SJ: Our relationship with the Indian Navy has been very good. We have gotten some very nice feedback from them. During the Techyard 2010 exhibition in Mumbai we were visited by the Indian Minister of Defense and afterwards we were invited to the big gala dinner to celebrate the 275 th anniversary of the Indian Navy. Our relationship with our local agent, Tri Marine, has also been very good. They have been very helpful in getting everything running at the start of the project. H: Do the projects in India take up all of your time? SJ: I also fulfill other tasks in Technical Services, but the India project is the main focus of my job. I have an overview of everything concerning the Navy programs and both offices there. Like most Technical Services members I know what it is to be a diver. This allows me to respond easily to certain situations that come up during a job. I have a good reality of an operation. I often notice this when talking to a customer. People are immediately aware that you have been a diver and know what this entails. I can react to their questions and problems in a more direct manner. I think that customers can also notice that I love doing my job. Once you enter the maritime sector, it never lets you go because it is so fascinating. In its quest to provide cost effective services to customers, Hydrex developed procedures to address different kinds of damage to propellers. This research led to the design of the Hydrex cold straightening machines first used in 2002. By taking advantage of this technique damaged blades can be straightened underwater, allowing the ship to return to commercial operations without the need to drydock. Blades can be brought back close to their original form, restoring the propeller s optimum efficiency. The cold straightening machines have been in use for quite some time now but the Hydrex research department has been looking into ways to 26 H: What are the plans for the future for the offices in India? SJ: First of all, we will make sure that the relationship with the Indian Navy remains as good as it is now. Whenever they need our assistance with one of their vessels we will help find a solution for them. We also want to expand our reaches into the commercial shipping business in India and the rest of Asia. India is one of the fastest growing countries in the world and the shipping industry in that region is a tremendous market to which we can offer our complete range of repair and maintenance services. In short, we want to keep the ships in India in business, as is our goal in the rest of the world. H: Thank you for the interview. People are immediately aware that you have been a diver and know what this entails. I can react to their questions and problems in a more direct manner. COLD STRAIGHTENING OF SEVERELY BENT PROPELLER BLADES expand the technique even further to improve our services. A new version of the straightening machine was recently put into practice. It is compatible with the existing models and is used to restore more severely bent propeller blades to their original condition.
Permanent rudder repairs now possible without drydocking Hydrex has developed an entirely new method enabling permanent repairs of rudders without drydocking the ship. Permanent repairs were hitherto not possible and ships had to drydock in case a major defect was found. The newly designed equipment is lightweight and can be mobilized very rapidly in our special flight containers. Therefore this new service is now available worldwide. Major defects on rudders very often cause unscheduled drydocking of ships. The new method designed by our technical department allows engineers, welders and inspectors to perform their tasks in dry conditions. Class approved permanent repairs in-situ, without moving the ship, are now possible and commercial operations can continue. Steel repairs and replacements can be performed and pintle and bushing defects can be solved without the loss of time and money associated with drydocking. The equipment can be mobilized within hours to any port in the world and is available for rapid mobilization from the Hydrex headquarters in Antwerp. 27
Keeping ships in business Hydrex underwater technology and services provide high quality solutions to the repair and replacement problems encountered by ships and offshore vessels. We deliver a complete line of services that may reduce or avoid off-hire time entirely. From major projects to simple inspections, Hydrex has the worldwide facilities and capability to meet your demands. Drydocking is not necessary so time, trouble and expense are saved by doing work in-situ. Hydrex services cover highly technical major repairs or replacements of a ship s external underwater equipment such as thrusters, propellers, rudders, stern tube seals and damaged or corroded hulls. Headquarters Hydrex N.V. - Antwerp Phone: + 32 3 213 5300 (24/7) E-mail: hydrex@hydrex.be Hydrex Spain - Algeciras Phone: + 34 (956) 675 049 (24/7) E-mail: info@hydrex.es Hydrex LLC - Tampa, U.S.A. Phone: + 1 727 443 3900 (24/7) E-mail: info@hydrex.us Hydrex West Africa Port Gentil, Gabon Phone: + 241 04 16 49 48 (24/7) E-mail: westafrica@hydrex.be www.hydrex.be Hydrex India - Mumbai Phone: + 91 222 2046 988 (24/7) E-mail: mumbai@hydrex.be Hydrex India -Vishakhaptnam Phone: + 91 891 2711 863 (24/7) E-mail: vishakhapatnam@hydrex.be