Fast underwater repair and maintenance services keep ships out of drydock

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 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

KEEPING SHIPS

IN BUSINESS

Underwater services and technology approved by:

ISO 9001 : 2008

Contents
Fast underwater repair and maintenance services keep ships out of drydock 2-3

Taking care of the entire underwater ship

4-5

Underwater maintenance services

6-7

Underwater repair services

8 - 20

Turnkey repair and maintenance solutions for the offshore industry 21 - 23

Ecospeed ship hull performance technology 24 - 25

Fast underwater repair and maintena

H
ydrex offers turnkey underwater repair solutions to shipowners wherever and whenever they are needed. Hydrexs multi-disciplinary team will help you find the best solution for any problem encountered with your ship below the water line. We will immediately mobilize our diver/technicians to carry out necessary repair work without the need to drydock. At Hydrex, we have a long and successful track record of performing complex permanent underwater repairs to thrusters, propellers, rudders, stern tube seals and damaged or corroded hulls. In fact we pioneered most of these more complex operations which once used to require drydocking but can now be carried out with the vessel afloat. By creating drydock-like conditions around the affected area, our diver/technicians can carry out these operations on vessels in port or at anchor. This permits normal commercial activities to continue without disruption, eliminating the loss of time, production and income that drydocking entails, as well as saving the enormous expense of drydocking itself. All the projects we undertake are engineered and carried out in close cooperation with the customer and any third party suppliers. They begin with evaluating the feasibility of an underwater repair, continue through design and construction of customized equipment and go all the way through to successful execution of the repair or

Contact

Damage

Job Estimation

Customer Communication

Workstation Setup

Problem Solved
2

nce services keep ships out of drydock

replacement and subsequent follow-up. We take on, organize and execute the entire job, start to finish, relieving the customer of all the hassle of coordination, planning and supervision. All Hydrex diver/technicians are trained and qualified to perform the full range of required class-approved repair procedures in even the harshest conditions. We have found that an effective, competent team is the only way to consistently achieve a high quality result in the short periods of time usually available to ships with a tight schedule to maintain. Through an ever-expanding, worldwide network of offices, Hydrex can provide these start to finish solutions economically at any location. Headquartered in the Belgian port of Antwerp, we have offices in Tampa (U.S.A), Algeciras (Spain), Mumbai and Vishakhapatnam (India), and Port Gentil (Gabon). And the list is growing as the demand for cost-effective localized services increases. All Hydrex offices have fully operational fast response centers where an extensive range of state-of-the-art equipment is available at all times for immediate deployment with our skilled diver/technician teams to wherever they are needed. Call us 24/7 with your underwater repair needs, routine or emergency, and we will help you get under way again rapidly without the need of a costly drydocking.

Logistics

Engineering

Underwater Preparation Back in Business

Operation

Customer Review
3

Taking care of the en

KEEPING SHIPS

IN BUSINESS

tire underwater ship

Underwater maintenance
H
ydrex offers maintenance services on a worldwide basis to help shipowners to optimize the performance of their vessels. The global Hydrex network can manage all required underwater inspections and maintenance services. All operations are performed by recognized Hydrex service stations and Hydrex will take full responsibility for the planning of the operations, arranging all permits and implementation of safety procedures. Full reports will be submitted for all operations. These required operations will be carried out in the most economic locations in close cooperation with the operator/manager of the vessel. Full coordination will be maintained with all parties involved so that maintenance work can be combined with technical operations to avoid unnecessary extra mod/demob costs.

condition and consequently its performance, with only a minimum of work on their part. The hull monitoring program developed by Hydrex allows companies to easily keep track of all the vessels under their care. Regular inspections and maintenance of these vessels is an integral part of the program. The entire planning and organization of these operations is handled by Hydrex and is tailored to fit the needs of each specific shipowner and his or her vessel(s). With fuel costs amounting to 40% of operational expenses and continuing to rise, reducing fuel consumption is a vital concern of shipowners. This is the

reason why hull monitoring pays for itself. Underwater hull roughness, marine fouling, bent propellers and poor paint condition are all factors that will increase fuel usage due to the drag or inefficiency created by the damaged or affected area. Carrying out preventive maintenance actions keeps a vessel in the best condition possible and can even result in an increase of the optimum performance of the ship over time as more data becomes available from the hull monitoring program. This technical management of the underwater hull of vessels is available on a worldwide basis thanks to the

Surveys: underwater hull monitoring

Building upon conventional technical skills and know-how while also taking advantage of the latest technology, Hydrex offers a unique hull monitoring service to its customers. This gives shipowners total control of their ship's hull

services
Hydrex network of offices and service stations. It will help improve a vessel's hull efficiency and in doing so offer substantial savings in fuel and maintenance costs.

Underwater ship hull cleaning

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 without the need for drydocking. This service is offered on a worldwide basis through a network of underwater hull cleaning stations strategically located around the planet. The unique design of the Hydrex series of underwater hull cleaning units provides the efficiency and durability demanded by the harsh underwater environment. All systems are carefully constructed so that no damage will occur to those hull coatings which are suitable for underwater cleaning, while still completely removing all types of fouling. This restores a vessels performance to as close to its optimum condition as possible and offers shipowners considerable savings in fuel. Hydrex has a policy not to carry out underwater cleaning activities which result in an increase of pollution by spreading large amounts of toxic materials used in many underwater hull coatings. Please contact us for further information

developed in-house specifically for propeller maintenance. Research has shown that propeller fouling can quickly reduce available horsepower by 20%. While rough propellers can be as destructive of fuel economy as rough hulls, the remedy is much cheaper and quicker. In economic terms, propeller maintenance yields a high return for a really small investment. Research carried out with a propeller

performance analysis tool showed that significant losses resulting from blade roughening can be recovered by thorough cleaning and polishing of the blades. It is therefore advised to perform propeller polishing at regular intervals to avoid losing propulsion efficiency and to keep the propeller in optimum operational condition. Hydrex combines this service with underwater inspections where this is economically advantageous to the shipowner or operator.

Propeller maintenance
Thanks to its network of offices and service stations, Hydrex can offer propeller polishings on a worldwide basis. These operations are carried out using underwater equipment designed and
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Underwater repair services

1. Seal repair and replacement

ydrex has carried out repairs and replacements on all types of seals underwater and on-site for a number of years now. Hydrex has developed the technology that enables seal replacements to be done underwater. By creating a dry underwater working environment around a seal assembly, repair work on the assembly is facilitated. It enables the replacement of damaged seals on-site. Prior to this technology it was usually necessary to go into drydock for this kind of operation, along with all the attendant loss of time and money. In the summer of 1996, Hydrex divers carried out an underwater face seal replacement on a Ro-Ro vessel. Face seal replacements had previously been practiced by our divers in the Antwerp workshop, but now they were able to actually perform this task while in the water. Since then Hydrex has constantly worked to advance the techniques used for stern tube seal repairs. In 1998 our divers completed a seal repair training course led by John Crane Marine, who also worked together with Hydrex in the testing of new developments. At the end of 1999

we successfully started working on injections with lip type stern tube seals. The next year Blohm & Voss gave our divers a training course to perform operations on their Simplex seals and in the same year we started doing tests for wet bonding on lip type seals. These tests showed us that wet bonding could only give us an 80% result compared with dry bonding. Instead of giving up on replacing lip type seals underwater, we started working on a method to avoid wet bonding and still do the seal repairs underwater. This led to the development of our unique flexible mobdock technique in 2002, which allowed us to create a dry working environment underwater and took us an important step forward. For the first time it became possible to entirely replace stern tube seals under water. In 2006 Hydrex entered into partnership with Aegir-Marine, providing us with the technical knowledge to repair or replace all the major seal types. Since then Hydrex has continued to develop the mobdock technique to adapt it to all possible situations. The technique has won one of the pres8

tigious Lloyds List Awards on two occasions. Several major classification societies have also awarded Hydrex certificates that accept the Hydrex revolutionary flexible mobdock technique to perform permanent underwater seal repairs. The following case studies give an account of some of the more important recent seal repairs performed by Hydrex.

Underwater stern tube seal repairs in France

The Hydrex flexible mobdock technique was used to reposition the aft stern tube seal assembly of a 210-meter

container ship in Le Havre. A Hydrex diver/technician team performed this operation to stop an oil blockage that occurred just after the vessel came out of drydock. After the rope guard was removed the diver/technicians discovered that the oil flow through the stern tube seal assembly was blocked because part of the assembly had been positioned 180 degrees the wrong way. A further inspection revealed that all seals were in good condition but that the bonding was faulty. The seals were therefore rebonded and the seal assembly refitted correctly. The superintendent of the container ship was very satisfied with the service offered by Hydrex. He said, Even after the typical late call on a Friday afternoon and even later that evening, Hydrex still managed to assemble and organize a team of divers that arrived the next day in Le Havre. The job was completed after four days, including full re-welding of the rope guard and shifting of the vessel to another berth.

Typhoon does not stop stern tube seal repair in the Philippines
When an oil leak prevented a 225-meter bulker from continuing its sailing schedule, a Hydrex diver/technician team mobilized to Manila together with one of the companys flexible mobdocks to perform emergency underwater repairs at anchorage. A typhoon was crossing over the Philippines at the time the team arrived. The storm grew to a climax just after preparations had been made for the repair. Unfortunately this delayed the underwater operation by a day. The team continued the operation when the weather had im-

proved slightly and full safety could be guaranteed for the divers. Even though they were forced to halt the repair briefly during the peak of the typhoon, the team worked through the rest of the storm to make sure that the delay for the customer was kept to an absolute minimum. Very strict safety measures were taken during the entire operation, as is the case with every job Hydrex performs.

Fast response prevents time loss for general cargo vessel in the U.S.A.
When oil was leaking from the stern tube seals of a general cargo vessel, Hydrex mobilized a certified diver/ technician team to the vessels location in Mobile, Alabama, to perform underwater stern tube seal repairs before the ship was transferred to a new chartering party. Because the U.S. Coast Guard has very strict policies concerning environmental risks, they would not allow the vessel to sail to a different location before the oil leak had been permanently fixed. In order to provide the customer with the fastest possible response, flexibility was essential throughout the entire operation. Hydrex was able to perform the repairs in a very tight timeframe and made sure that the new charterer could sail the vessel free of oil leaks.

Underwater stern tube seal repair in Panama

When a 295-meter container ship developed an oil leak from its stern tube seal assembly, caused by an entangled fishing net, Hydrex mobilized a diver/ technician team to Panama where underwater repairs were carried out using the Hydrex unique flexible mobdock technique. Working closely together with a local support base, three seals were replaced in one smooth operation while the vessel was anchored at the entrance to the Panama Canal. Corrosion on the running area of the seals prevented the new stern tube seals from completely closing off the inside of the ship, so the decision was made to remove the spacer ring. This adjustment brought the seals beyond the corroded area.

2. Thruster repair and replacement

ydrex can assist shipowners with almost any problem they encounter with their vessels thruster. A wide range of repair or maintenance work can be carried out to all types of thrusters. An entire unit can be overhauled, propeller blades or seals can be replaced or repair work on a specific part of a thruster can be performed by Hydrex diver/technicians on-site. All of these repairs can be carried out without the need to drydock the vessel. Hydrex was the first company to show that it was possible to remove and then replace thrusters by creating a dry environment underwater. Using the Hydrex-developed steel mobdocks to seal off the thruster tunnel, with an access shaft protruding above the water, work teams accessed the thruster tunnel and removed or repaired the thruster within the tunnel in complete safety. This was done in conditions similar to those above water. Hydrex has since then developed this technology further using lightweight flexible mobdocks. These modernized mobdocks, which are designed to be easily transported around the world,

are used to close off the thruster tunnel on both sides. This allows divers to work in a dry environment around the unit. Hydrex has also developed 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 faster and more easily. 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. In the last few years Hydrex divers have carried out thruster operations on numerous occasions around the world. Some case in point.

Underwater bow thruster replacements on several container vessels in Singapore

When a 300-meter container vessel lost the blades of its bow thruster, Hydrex was asked to remove the damaged thruster and replace it with a spare one. The operation was carried out while the vessel was at anchor in Singapore. Because of the tight schedule of the ship, the entire operation was planned and launched as rapidly as possible. Just days after the order was confirmed, the equipment and eight
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Hydrex diver/technicians arrived in Singapore. During this operation the diver/technician teams worked in shifts to make sure that the repair would be finished before the vessel had to depart and this despite the unavoidable loss of time that poor weather conditions brought about. The vessel could once again use its thruster to maneuver inside ports without depending on external assistance. Also in Singapore, a Hydrex diver/ technician team reinstalled the overhauled bow thruster of a 280-meter container vessel underwater with the use of the Hydrex flexible mobdock four months after they had removed the unit. The superintendent of the ship was very satisfied with the first part of the operation. He said that ...the job was completed well within the timeframe of forty hours thanks to good team work of the Hydrex divers, the ship staff and the floating crane operator. For this reason the customer asked Hydrex to take care of the reinstallation as well.

Bow thruster removal and reinstallation in several stages across Europe

Closer to home Hydrex carried out the removal, transportation and reinstallation of a bow thruster unit in stages in several locations to allow the vessel

to keep to its sailing schedule. A 334-meter container vessel had to use the services of a tug boat for port maneuvering due to a malfunctioning thruster unit, and its owners commissioned Hydrex to take care of the entire overhaul.The operation was carried out in Rotterdam, Southampton, Le Havre, Dunkirk, Hamburg and finally Rotterdam and Southampton again. Despite these multiple locations, the delay for the customer was reduced to the absolute minimum. The removal and reinstallation of the bow thruster unit underwater made it unnecessary for the vessel to go into drydock.

class approved operation on the heavylift, semi-sub crane vessel Saipem 7000. The inspection and the underwater removal and reinstallation of one of its 60-ton azimuth thrusters were performed in Cartagena, Spain. Hydrex had performed maintenance and repair work for this customer before. Familiar with our procedures, he asked us to send an experienced and fully certified diver/technician team to carry out a detailed and high quality underwater inspection and azimuth thruster removal. According to Mr. Maarten Heitling, the customers Manager Lifting Fleet, ...the work went very well. The team and equipment were readily available for the task and the operation was carried out in a safe, professional and time-efficient manner, which is not less than what we have grown to expect from Hydrex.

Removal and reinstallation of azimuth thruster in Spain

Hydrex mobilized equipment and a diver/technician team to perform a
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3. Rudder repair

he latest development of the flexible mobdock technique allows Hydrex to perform permanent repairs on any type of rudder while the vessel remains at anchorage and cargo operations can continue. Permanent in-water rudder repairs were hitherto not possible and ships had to drydock in cases where a major defect was found. The newlydesigned equipment is lightweight and can be mobilized within hours to any port in the world. This allows Hydrex to offer this new service on a worldwide basis.

Major defects on rudders very often cause unscheduled drydocking of ships. The new technique designed by the Hydrex technical department allows engineers, welders and inspectors to perform their tasks in dry conditions with the vessel still afloat. Class approved permanent repairs on-site are now possible while commercial operations 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 at the Hydrex headquarters in Antwerp and at the offices in Tampa, Algeciras, Mumbai, Visakhapatnam and Port Gentil. Prior to the development of this technique, Hydrex had carried out rudder operations for a number of years. Some cases in point.

Zeebruges, Belgium. A detailed inspection revealed the damage to be far worse than expected. The Hydrex technical department devised a plan that would enable the owner to sail for the next three months until the next drydocking when comprehensive permanent repairs would be made. The entire operation was performed according to the Hydrex standard underwater welding procedures and was accepted by the class on the condition that regular inspections were performed until the drydocking. The damage to the rudder was considerably more severe than originally thought and the repairs

required became more extensive. Our technical and design departments have the experience and knowledge to deal with this kind of situation and our underwater repair teams are trained to adapt to changing circumstances.

Rudder alignment in U.S.A.

Hydrex performed an inspection and realignment of the rudder of a 245meter 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 its stop in Fairground in the Gulf of Mexico. After the team carried out a comprehensive inspection of the rudder it was confirmed that its indicated pitch position was not in accordance with its actual pitch position. Therefore the rudder needed to be realigned. No other damage was found on the rudder so that no further repairs were necessary. Because such an operation was not allowed at the vessels location the decision was made to move the vessel to Mobile, Alabama. During the opera-

Complex underwater rudder repair in Belgium

Hydrex was asked to perform crack repair on a 228-meter vehicle carrier during the vessels stop in the port of
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tion, the team worked in shifts around the clock to finish the operation as soon as possible and avoid any additional loss of time for the customer.

Multiple jobs performed on cruise ship in Germany

After experiencing problems with the rudder of their 293-meter cruise ship, the owners asked Hydrex to perform a detailed underwater inspection during the ships stay in the Azores and to design a plan for any possible underwater repairs. At the same time it was also requested to arrange for the replacement of a propeller blade that had been damaged and repaired earlier but was still causing speed loss. The survey revealed that the lower pintle of the hinged flap rudder was missing which caused the bottom of the flap to shift out of its normal position, thereby

blocking the mechanism. Luckily the hinges had not come apart completely, which would have meant that the entire flap would have inevitably detached itself from the rudder. It was decided to perform both repairs during the vessels next scheduled stop in Kiel, Germany. By working in two teams and in shifts, Hydrex was able to finish both repairs at the same time and within 36 hours, far less than the available time frame.

Rudder seal replacement in Belgium

When a 170-meter ro/ro vessel experienced leaking rudder stock seals, Hydrex mobilized a technician team to replace the seals when the vessel docked close to the companys headquarters in Antwerp. To give the team access to the lower rudder stock seals the crew trimmed the vessel as much as possible. The Hydrex technicians then installed a pontoon around the rudder blade and made all necessary preparations for the operation. After the seal area had been cleaned, a detailed inspection revealed that one of the old seal rings was not bonded and that the second had come completely loose. The team removed the old seals. After positioning and bonding the new seals, they reinstalled the flange and bolts and secured them with wire. This concluded the operation. Hydrex has many years of experience with the repair and replacement of all types of seals on site. This prevents the need to take a vessel into drydock, along with all the attendant loss of time and money this would bring about.

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4. Propeller repair and modification

ship with bent or cracked propeller blades might experience severe vibrations while sailing. The classification society might demand a repair before the vessel is allowed to sail on. By straightening the blades or cropping them, Hydrex can restore the propellers balance, resulting in a green light from the class for the vessel. Prior to a propeller repair, a detailed underwater inspection is carried out by Hydrex diver/technicians. They are certified to make a full assessment of the condition of the propeller. The exact dimensions and position of the damage can then be communicated to the Hydrex technical department supervising the operation. This is essential because the calculations need to be perfectly accurate to achieve an ideal result with the repair. Hydrex team members are not only divers, but have experience in dealing with all kinds of different situations and circumstances. They are trained to think with the people in the technical department. As diver/technician experts, they

can assist in working out the best solution and have the skill and experience needed to implement the theoretical solutions that have been worked out.

Blade straightening
By taking advantage of the in-house developed cold straightening technique, damaged blades can be straightened underwater, allowing the ship

to return to commercial operations without the need to drydock. Optimum efficiency of the propellers can be restored by bringing the blades back close to their original form. The cold straightening machine has been in use for quite some time now but the Hydrex research department has been looking into ways to enhance the technique even further to improve our services. A new model of the straightening machine was recently put into service. It is compatible with the existing model and is used to restore more severely bent propeller blades.

Cropping
If straightening is not an option, the affected area on the blade will be cropped to restore the hydrodynamic balance. This is done to achieve the greatest possible efficiency for the vessel. This kind of repair is carried out with the propeller blade cutting equipment that was also developed by the Hydrex research department. First a detailed underwater inspection is performed by a Hydrex diver/technician team to obtain the exact parameters of the damage which are then used

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give the blades extra strength and make them less susceptible to damage from ice or other debris. This was done by modifying the blades to a very specific design that made them less prone to damage while keeping the performance of the propeller as close to optimum as possible. The operation was performed in close communication with the manufacturer of the propellers. Some cases in point.

Simultaneous stern tube seal and propeller repair on vessel in New York
A Hydrex diver/technician team replaced three seals on a 180-meter tanker berthed in New York while concurrently cropping two of its propeller blades to restore balance to the propeller. Both operations were carried out at the same time while the ship was trimmed and at some 60 meters from the quayside. One of the blades had been severely bent and had suffered several cracks, which ruled out any possibility of straightening it. The team made an exact assessment of the damage and used these measurements to find the best cutting line. They then cut the damaged blade after which they cut the opposite blade at exactly the same place. Besides carrying out both parts of the operation simultaneously, the team also worked in shifts to limit the off-hire time of the vessel. This allowed the superintendent to sail his vessel again with both its propeller and stern tube seals back intact with only a minimal delay.

for a detailed calculation of the ideal cutting line. This allows the customer to know in advance what the result of the operation will be. He can then make an informed decision.

both above and below the waterline, anywhere in the world and sometimes even in the most extreme conditions. Hydrex not only offers repair services, but can also help customers when they have the need for preventive or other special custom projects. At the end of 2010, for example, preventive modifications were made in Bremerhaven to the blades of three ice-going sister vessels. When several of this customers vessels suffered damage and the propellers needed cropping after the 2009-2010 winter, the owner wanted to find a way to prevent this from occurring to his other container vessels. When the 2010-2011 winter promised to be equally harsh, he wanted to

Restoring optimum propeller performance

Both cropping and straightening are done to restore the propellers performance to as close to its optimum condition as possible and to balance it. This can help a vessel that is suffering loss of speed due to an out-of-balance propeller. Propeller optimization is sometimes also done to restore the performance even if no real damage has occurred, as after some years of service an engine sometimes loses some of its performance. By calculating the possibilities of a propeller optimization the performance can be restored. Hydrex has been cropping propellers since 1985 and straightening them since 2000. On some occasions an entire blade has to be replaced on a variable pitch propeller. This work can also be carried out by our divers who are trained to perform a wide variety of operations,

Combined cold straightening and cropping 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

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measurements. All three parts of the operation were performed in one day, avoiding any delay for the customer.

Cold straightening in Rotterdam

The crew of a 183-meter tanker suspected that there was damage to their vessels propeller blades caused by sailing through ice. An underwater inspection carried out by a Hydrex team confirmed this to be the case. The vessel was therefore trimmed during its stay in Rotterdam, and the team straightened the bent propeller blade tip. This restored the blade to its original condition.

Propeller blade cropping on ro/ro vessel in Panama

When a blade is damaged too severely by ice or other floating debris, straightening is not feasible. If it is decided that cropping is the only option, measurements are taken and used to calculate the exact radius of the area to be cropped. This was the case with the propeller blades of a 197-meter ro/ro vessel. A Hydrex diver/technician team mobilized from the office in Clearwater, U.S.A. to assist the vessel in Panama. To make a full assessment of the damage, the team first performed an underwater inspection. They then used the information acquired to find the best cutting line that would bring the performance of the propeller back as close to its optimal condition as possible. The actual repair job consisted of the four blades being modified underwater one after the other by the Hydrex diver/technicians. The area to be cropped was marked out on each blade and verified. The blade was then cropped and its edge ground to give it the correct radius. When the cropping was complete, the blades were polished to make sure that any remaining loss of efficiency would be minimal.

straightening machine to bring the bent blades back to their original shape. They used the measurements taken during a detailed inspection to calculate the most economical cutting line for the cropping. This made sure that the propellers balance was restored.

formed an inspection of the propeller and discovered a crack on the leading edge of one of the blades. The crack was ground out and its edge was smoothed. The operation was concluded with the performance of pintle

Propeller blade repair and rope guard replacement in Algeciras

A Hydrex diver/technician team mobilized with one of the companys workboats from the Algeciras office to perform a rope guard replacement, a propeller blade repair and a shaft wear-down reading on a 183-meter tanker while the vessel was at anchor in the bay. The operation was carried out in the dry while the vessel was trimmed. The team first installed a platform around the stern to give the Hydrex technicians access to the stern tube seal assembly and the propeller. They then removed the old rope guard and positioned the replacement and bolted it in place. Next the team per16

5. Hull repair

ydrex on-site hull repair services include the renewal of both small and large areas of damaged hull plating. These repairs can be carried out above or below water, according to the circumstances, with tailor-made mobdocks no need for drydocking. Normal commercial activities can therefore continue without disruption. These operations follow the Hydrex procedure for welding cracks in the vessel's shell plating and they are approved by the major classification societies.

Hydrex diver/technician teams carry out these on-site hull repairs all over the world. In most cases the damaged area can be replaced with a permanent insert and no condition of class is imposed. On the rare occasions where the damage does not allow such a repair, a temporary doubler plate is installed over the affected area. This allows the owners to keep to their schedule until the next scheduled drydock visit when they can arrange a permanent repair. Building on an ever-expanding worldwide network of offices and support bases, Hydrex can provide these

repairs at reasonable costs across the globe. All offices are fully equipped and can mobilize immediately. As part of the Hydrex Group they can draw on the companys combined technical expertise and many years of experience for advice and direction. Repairs of this kind can only be done successfully by trained divers/technicians who are familiar with them and who have the relevant know-how to

resolve all of the technical difficulties encountered during underwater operations. This is why all Hydrex technical staff from all offices undergo stringent training on a wide range of operations. They can all achieve the same high quality without unnecessary loss of time. The following case studies give an account of two important hull repairs recently carried out by Hydrex.

A worlds first in underwater repair: the insertion of a complete, prefabricated replacement hull section in a badly damaged ship at anchor.
On Friday 22nd July, 2011 the Tsavliris Salvage Group urgently dispatched salvage tug Stevns Battler in response to a call for assistance from bulk carrier Navios Sagittarius (GRT: 38,849, DWT: 75,756), laden with 73,419 metric tons of iron ore pellets. The Sagittarius had run aground on the Tonneberg Banke, about 23.5 miles east of Frederikshavn, Denmark, while on passage from Finland to China.
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was Hydrex. Captain George Polychroniou, Tsavliris Operations Manager confirmed that, The cooperation with Hydrex was excellent. This was particularly important in a complex salvage operation which lasted three months and for which Hydrex mobilized 24 divers full time, in two shifts, for the duration of the operation. Without accurate measurements and data, the naval architects could not produce drawings and plans which would work. So the first step for the Hydrex divers was to get accurate measurements for the two major areas of damage (one near the forepeak, the other further aft, both on the port side), on a hull that was badly deformed, pierced, torn and indented. Using these measurements and the original drawings of the ship, the naval architects were then able to produce final drawings from which a section and a doubler plate could be fabricated and installed. As fabrication of the section and the doubler plate was completed, preparation for installation began. In the case of the section it was necessary to cut On July 26th, a salvage plan was approved by the Danish authorities and on July 28th, after about 3,000 tons of cargo had been transferred to the lightering vessel, by pressurizing certain tanks and with the assistance of tugs, the Sagittarius was refloated. The vessel was then towed to Frederikshaven for a detailed underwater inspection, extensive bottom repairs, and reloading of cargo. Tsavliris had signed a Lloyds Open Form salvage contract with Navios and subcontracted several companies to carry out inspection and repairs. The chief subcontracting company for the inspection, planning and repair work
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150 meters after a grounding in the Suez Canal, a large crack 1.5 meters long appeared, making it impossible for the vessel to sail any further. To close off the crack and allow the vessel to continue its route, Hydrex sent a nine man diver/technician team to the vessels location, 21 miles off the coast of Fujairah, United Arabian Emirates. The ship had suffered very extensive grounding damage while leaving the Suez Canal, indenting the underwater hull on the starboard side over half the total length of the ship and up to six meters deep, compressing the shell plating and seriously weakening the strength of the hull. Luckily the damage only covered the first three ballast tanks, for had it reached the fourth tank or the cargo hold, there was risk that the ship would have sunk. As the situation now stood, only some small cracks were present and no leakages. The ship was allowed to sail on to its next stop in Fujairah were unfortunately a large crack appeared. This was a consequence of the movement of the indented plating during the journey. The additional damage and consequent water ingress made it impossible for

through the hull plates where the hull was distorted and broken. Divers proceeded to cut a hole in the hull about 5 x 5 meters in size. The prefabricated insert was lowered into the water by the crane barge which was used throughout the operation, and pulled into place with chain blocks. While work was going ahead with the section, another Hydrex team worked on the fabrication and installation of the 8 x 1.8 m doubler plate in the area of DBBT No. 1. The frame was fabricated and used for measurement and then the plate itself was cut and attached. As a note, speed was of the essence in this job as the ship was on a long term charter and each day it was out of service was costing tens of thousands of dollars. It is, as far as we know, the first time that an entire hull section has been prefabricated and inserted into a ships hull, cutting away the existing damaged plates, with the ship still

afloat, thus permitting the vessel to continue on a major voyage without the need to drydock.

Underwater repairs in the U.A.E. allow ship to sail on after a 150-meter large grounding damage
When the shell plating of a 300-meter bulker was indented over a length of

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the vessel to continue to China for unloading until the crack was repaired sufficiently to avert the risk of any further damage. After the customer contacted us, one of our technicians flew to Fujairah for a preliminary inspection of the damage. This was essential in order to create a repair plan that would offer the customer the best possible solution for this specific problem. This plan was designed in cooperation with a naval architect. Next it was proposed to the customer who gladly approved it. The leakage had lowered the fully loaded ship from a draft of 18 meters to 22 meters. Because such a water depth means shorter diving intervals, a large diving team was immediately mobilized to the vessel to allow the team to work continuously for the 12 hours that were available each day. To get a perfect assessment of the way the shell plating had been compressed, a special frame was made and secured over the damaged area. This allowed the diver/technician team to get exact measurements of the distorted plating.

These measurements were then used to create a special cofferdam that would cover the crack and prevent it from growing further. After the cofferdam had been positioned and secured, it was reinforced with longitudinal stiffeners and additional fortifications until it was strong enough to hold the water pressure. The tank behind the crack was then

emptied, bringing the vessel back to its previous draft of 18 meters. In total the reinforcements covered an area of 18m2 and the combined length of all the welds was over 500 m. When the operation was finished, only a few reinforcements needed to be added to the inside of the hull to prepare the ship for its journey to China.

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Turnkey repair and maintenance solutions for the offshore industry

H
ydrex is capable of carrying out high quality and fast underwater inspection and cleaning operations or any other maintenance and repair work on offshore units. A Hydrex diver/technician team can be on location and ready to service offshore units or offshore related vessels within days. By taking advantage of Hydrexs inhouse designed range of cleaning units, all types of fouling can be removed from any type of offshore structure. This offers owners big savings in fuel when moving their unit from one location to another which also means reduced GHG and other emissions. It also reduces drag and weight on the unit and facilitates any needed full scale inspection. For offshore cleaning operations an all-embracing combination of single, twin and triple head cleaning machines is used. The twin head 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 machine on the other hand is easily adaptable to the flat shapes of a ship or pontoon hull. It has a reverse function and its heads self-adjust to the contours of the hull making it far easier to clean complex areas. Preventive and protective maintenance services can also be provided. These 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. Hydrex also has the know-how and expertise to provide comprehensive on-site repair services and project management for offshore related units. These services include a wide range of possible repair operations that make use of specially designed cofferdams. These can be rigid or flexible depending on the type of repair. All 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 followup.
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Some cases in point.

Replacement of azimuth thruster on crane barge in Gabon

A Hydrex diver/technician team mobilized to an offshore crane barge stationed at its service base in Gabon to replace one of the vessels swing-up azimuth thrusters with the spare. The operation had to be carried out in a very short timeframe because the crane barge was scheduled to leave for an operation in Nigeria. All repairs and other servicing needed to be performed before the start of this operation. For this reason going to drydock was not an option as the nearest suitable location

Underwater maintenance work performed on drill ships in the Gulf of Mexico

Hydrex carried out a full inspection and removed all fouling from three drilling vessels in the Gulf of Mexico owned by Transocean, the worlds was South Africa and this would have taken the repairs far beyond the available time frame. Hydrex had carried out a similar operation on this vessel on two occasions. Four years ago when the first azimuth thruster was replaced, a large mobdock (measuring 9 x 6 x 2 meters and weighing over 25 tons by itself) was constructed under Hydrex supervision in Belgium and transported to Gabon. There it was stored after the repair. It was to be used at short notice whenever future repairs were required on thrusters. This allowed for a very fast mobilization and thruster replacement on the next two occasions. The operation was concluded well before the start of the barges next operation and presented a major saving in time and money for the owner as he did not have to take the offshore unit off hire to go to drydock.
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largest offshore drilling company. This was done to reduce the weight and drag of the vessels and increase their available deck load. 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

Underwater inspection of oil terminal in Al-Muajiz

A team of Hydrex diver/technicians performed inspection work on some sixty legs of an oil terminal located in Yanbu, just north of Al-Muajiz 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. 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. 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 inspection to a depth of thirty meters to the highest quality and safety standards.

take the vessels to drydock. Impressed by the complete package of both engineering and project management that Hydrex offers, Transocean 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 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 it could be overhauled. 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 customers program as much as possible instead of the other way around.

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Ecospeed Ship hull performance technology

cospeed is an environmentally safe hull coating system which improves a ships performance and provides it with longlasting protection. It consists of a unique, entirely original and thoroughly proven system that combines the advantages of a superior coating applied by a specialized method, a surface treatment for hydrodynamic optimization and a long term underwater maintenance service system.

Ecospeed is a vinyl ester with a high concentration of embedded glass platelets. It has a very low amount of volatile organic compounds (VOC) and is typically applied in two coats of 500m dft. The high film thickness and the presence of glass platelets which act as an impermeable barrier explain why Ecospeed has excellent anti-corrosive properties. It is extremely durable, making it perfectly suited to be subjected to regular in-water surface treatment.

Once in a lifetime application

Ecospeed comes with a ten year guarantee and is expected to last the lifetime of the vessel. This is in strong contrast to traditional anti-fouling paints where a new application is necessary during each drydocking. With Ecospeed only one application is required and the cost of any future repaints is eliminated. Planning upcoming drydock sessions therefore becomes a far simpler procedure, giving shipowners the benefit of being able to focus on the technical maintenance of the vessel and reducing the time in drydock to the absolute minimum, which in turn results in less off-hire time.

TBT-free, copper-free, biocide-free and silicone oil free solution

In 2008, stringent tests were carried out within the framework of an EU LIFE demonstration project to provide scientific data and to authenticate the nontoxicity of the Ecospeed hull perfor24

mance technology. This research proved that the coating is 100% toxinfree and that there is no negative effect on the water quality or the marine environment at any point of its application or use. Moreover, the massive amounts of VOC and zinc anode emission associated with conventional hull coating systems are reduced to almost zero.

As part of the tests, comprehensive sampling was performed at the start, during and after the underwater cleaning of several ships. These samples were then examined. The results verified that there is no impact on the water as a result of the underwater maintenance, even in close proximity to the cleaning unit used. Because the water in the ports could have affected the tests and to verify the results, additional tests were performed in a lab in worst case scenario circumstances which led to the same conclusions. Examination of the samples showed that only marine fouling is removed during the cleaning process and that the Ecospeed coating stays intact and has no effect on its surroundings.

not degrade but gradually improves. This procedure is made easy by Ecospeeds technical properties. Cleaning can be carried out whenever needed, at any point in the coatings lifespan, without causing damage. Regular underwater cleaning of the coating results in improved hull smoothness each and every time the hull is cleaned. The coating will maintain its integrity at all times. Tests have shown that a very large number (+500) of repeated underwater hull cleanings improves its surface texture without any adverse effects. This will prevent any increase in fuel consumption over the years as would happen with traditional, active antifouling paints which are known to degrade

steadily over time. The ship hull can be kept close to its optimum hydrodynamic condition thereby producing major fuel savings.

Ecospeed improves with each underwater treatment

One of the many unique factors of this underwater hull coating system is that with repeated underwater hull cleaning, the coatings surface aspect does

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Fast underwater repair and maintenance services keep ships out of drydock

ydrex 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 on-site.

Hydrex services cover highly technical major repairs or replacements of a ships 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

Hydrex India - Mumbai Phone: + 91 222 2046 988 (24/7) E-mail: mumbai@hydrex.be Hydrex India -Vishakhapatnam Phone: + 91 891 2711 863 (24/7) E-mail: vishakhapatnam@hydrex.be

www.hydrex.be
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