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<strong>Active</strong> <strong>with</strong> <strong>jobs</strong> <strong>around</strong><br />

<strong>the</strong> <strong>world</strong><br />

<strong>Fast</strong> <strong>and</strong> <strong>easy</strong> <strong>Ecospeed</strong><br />

application offers many<br />

benefits for shipyards<br />

<strong>and</strong> shipowners<br />

NEWS<br />

LETTER | 186


Contents<br />

Page 3 - 9<br />

Three repairs carried out on<br />

general cargo vessel at<br />

anchorage in Gabon<br />

On-site propeller<br />

cropping in Ghent<br />

Underwater stern tube seal<br />

replacement on general<br />

cargo vessel in Las Palmas<br />

Page 12 - 18<br />

<strong>Fast</strong> <strong>and</strong> <strong>easy</strong> <strong>Ecospeed</strong><br />

application offers many benefits<br />

for shipyards <strong>and</strong> shipowners<br />

KEEPING SHIPS<br />

IN BUSINESS<br />

KEEPING SHIPS<br />

IN BUSINESS<br />

ISO 9001<br />

certified<br />

Underwater services <strong>and</strong><br />

technology approved by:<br />

Supreme Rudder<br />

Protection<br />

<strong>Ecospeed</strong> gives a very thorough<br />

<strong>and</strong> lasting defense<br />

against cavitation <strong>and</strong> corrosion<br />

damage for a ship hull’s entire<br />

service life.<br />

The coating equally provides <strong>the</strong><br />

rudder <strong>with</strong> an impenetrable pro-<br />

tective layer while its flexibility<br />

enables absorption of <strong>the</strong> forces<br />

that are produced by cavitation.<br />

This prevents <strong>the</strong> damage normally<br />

caused by this phenomenon.<br />

Without proper protection against<br />

cavitation <strong>and</strong> <strong>the</strong> resulting erosion<br />

<strong>and</strong> corrosion damage, <strong>the</strong><br />

Belgian headquarters<br />

Phone: + 32 3 213 5318<br />

Fax: + 32 3 213 5321<br />

info@ecospeed.be<br />

2<br />

financial consequences can be<br />

severe.<br />

By removing <strong>the</strong> existing paint<br />

layers <strong>and</strong> applying <strong>Ecospeed</strong><br />

on <strong>the</strong> rudder we can break <strong>the</strong><br />

never ending cycle of painting,<br />

suffering damage, having to per-<br />

form extensive repairs in drydock<br />

followed by a full repainting,<br />

again <strong>and</strong> again.<br />

With an <strong>Ecospeed</strong> application no<br />

full repaint will be needed during<br />

drydocking. <strong>Ecospeed</strong> is guaranteed<br />

for ten years. At <strong>the</strong> most,<br />

minor touch-ups will be required.<br />

US Office<br />

Phone: + 1 727 443 3900<br />

Fax: + 1 727 443 3990<br />

info@ecospeed.us<br />

www.ecospeed.be


Three repairs carried out on general<br />

cargo vessel at anchorage in Gabon<br />

Hydrex diver/technicians carried<br />

out three separate repairs on<br />

a 118-meter general cargo vessel<br />

while <strong>the</strong> ship was at anchorage<br />

off <strong>the</strong> coast of Port Gentil, Gabon.<br />

These on-site repairs allowed <strong>the</strong><br />

customer to save precious time<br />

<strong>and</strong> money.<br />

The entire operation was supervised<br />

<strong>and</strong> coordinated by <strong>the</strong> Hydrex team<br />

leader from inside a monitoring<br />

station.<br />

Bulbous bow repair<br />

A detailed inspection of both <strong>the</strong><br />

outside <strong>and</strong> inside of <strong>the</strong> bulbous<br />

bow revealed that <strong>the</strong> entire area<br />

had been damaged. The bottom<br />

of <strong>the</strong> bow was heavily indented<br />

<strong>Active</strong> <strong>with</strong> <strong>jobs</strong><br />

<strong>around</strong> <strong>the</strong> <strong>world</strong><br />

(see pictures on <strong>the</strong> right). This<br />

had caused serious deformation<br />

of <strong>the</strong> structural framework in <strong>the</strong><br />

forepeak of <strong>the</strong> vessel (see pictures<br />

below). There were also several<br />

cracks <strong>and</strong> small holes in <strong>the</strong> hull<br />

plating.<br />

The Hydrex team installed 14 larger<br />

doubler plates (see pictures at <strong>the</strong> top<br />

of page 4), as well as many smaller<br />

ones to close off <strong>the</strong> damaged area<br />

from <strong>the</strong> rest of <strong>the</strong> vessel <strong>and</strong> prevent<br />

leaks. Three additional frames<br />

were also installed to reinforce <strong>the</strong><br />

bulkhead <strong>and</strong> to make sure that<br />

<strong>the</strong> vessel could sail safely. Finally<br />

crack arrests were drilled to prevent<br />

<strong>the</strong> cracks from spreading<br />

any fur<strong>the</strong>r.<br />

There were serious deformations of <strong>the</strong> structural framework in <strong>the</strong> forepeak.<br />

3<br />

The bottom of <strong>the</strong> bulbous bow was<br />

heavily indented.


The Hydrex team installed 14 larger doubler frames, as well as many smaller ones.<br />

The Hydrex technicians cut away <strong>the</strong> old plating <strong>around</strong> <strong>the</strong> brackets on <strong>the</strong> port side of one of <strong>the</strong> guiding frames in <strong>the</strong><br />

cargo hold.<br />

The worn tubes (left) were also removed <strong>and</strong> replaced <strong>with</strong> new ones (right).<br />

4


The inserts in <strong>the</strong> cargo hold bottom<br />

plating were positioned <strong>and</strong> <strong>the</strong>n secured<br />

<strong>with</strong> a full penetration weld.<br />

Insert repairs in bottom<br />

plating<br />

To repair holes in <strong>the</strong> bottom plating<br />

of <strong>the</strong> cargo hold, <strong>the</strong> Hydrex diver/<br />

technicians installed two insert<br />

plates, measuring 600 x 600 mm <strong>and</strong><br />

500 x 450 mm (see pictures in <strong>the</strong><br />

top left corner of this page). After<br />

<strong>the</strong>y had cut away <strong>the</strong> damaged<br />

areas <strong>the</strong>y prepared <strong>the</strong> edges of<br />

both holes. Next <strong>the</strong> new inserts<br />

were positioned <strong>and</strong> kept in place<br />

<strong>with</strong> screw docks. A full penetration<br />

weld was <strong>the</strong>n used to secure <strong>the</strong><br />

plates, finishing <strong>the</strong> second part of<br />

<strong>the</strong> operation.<br />

Installation of new brackets<br />

on frame in cargo hold<br />

Simultaneously <strong>with</strong> <strong>the</strong> o<strong>the</strong>r<br />

two repairs, <strong>the</strong> Hydrex team also<br />

replaced plating of <strong>the</strong> damaged<br />

port side brackets of one of <strong>the</strong> large<br />

container guiding frames in <strong>the</strong> cargo<br />

hold (see pictures in <strong>the</strong> middle row<br />

of page 4). Pins are pushed through<br />

this plating <strong>and</strong> into tubes in <strong>the</strong><br />

hold wall to secure <strong>the</strong> frames. This<br />

allows <strong>the</strong> crew to reposition <strong>the</strong><br />

frames or remove <strong>the</strong>m according<br />

to <strong>the</strong> requirements of <strong>the</strong> cargo that<br />

is transported. The Hydrex techni-<br />

Hydrex installed two inserts in <strong>the</strong> cargo hold <strong>and</strong> several new brackets on one<br />

of <strong>the</strong> frames.<br />

New pins were also fabricated to fit inside <strong>the</strong> new plating <strong>and</strong> tubes behind it.<br />

5<br />

cians cut away <strong>the</strong> old plating on<br />

<strong>the</strong> frames as well as on <strong>the</strong> hold<br />

wall <strong>and</strong> installed new plating <strong>with</strong><br />

full penetration welds. They also<br />

replaced <strong>the</strong> old worn tubes in <strong>the</strong><br />

cargo hold wall <strong>and</strong> <strong>the</strong> securing<br />

pins <strong>with</strong> new ones (see pictures on<br />

<strong>the</strong> bottom row of page 4 <strong>and</strong> in <strong>the</strong><br />

top right corner of this page).<br />

Carrying out <strong>the</strong>se three repairs during<br />

one operation while <strong>the</strong> vessel<br />

was at anchorage illustrates <strong>the</strong> flexi-<br />

bility <strong>and</strong> professionalism of Hydrex<br />

<strong>and</strong> its staff members. The company’s<br />

goal has always been to keep a vessel<br />

out of drydock as much as possible<br />

<strong>and</strong> to carry out needed repairs or<br />

maintenance <strong>with</strong> <strong>the</strong> least possible<br />

interruption to <strong>the</strong> sailing schedule.<br />

With no drydock close by, this was<br />

extremely important for this customer.<br />

The Hydrex technical department<br />

has <strong>the</strong> know-how <strong>and</strong> experience to<br />

create tailor-made solutions for <strong>the</strong><br />

specific problems encountered by a<br />

shipowner, while <strong>the</strong> diver/technicians<br />

have been trained to perform<br />

<strong>the</strong>se operations in <strong>the</strong> shortest possible<br />

time frame <strong>and</strong> <strong>with</strong>out losing<br />

<strong>the</strong> quality Hydrex is known for.<br />

KEEPING SHIPS<br />

IN BUSINESS<br />

KEEPING SHIPS


When all four propeller<br />

blades of a 100-meter general<br />

cargo vessel were severely<br />

bent, a repair was required by<br />

<strong>the</strong> classification society. Hydrex<br />

<strong>the</strong>refore performed a detailed<br />

video inspection, followed by a<br />

repair while <strong>the</strong> vessel was ber<strong>the</strong>d<br />

in Ghent, Belgium.<br />

To make a full assessment of <strong>the</strong><br />

damage, <strong>the</strong> diver/technician team<br />

first performed a detailed underwater<br />

inspection of <strong>the</strong> blades. This revealed<br />

that one blade was bent over<br />

an angle of 15° while <strong>the</strong> o<strong>the</strong>r<br />

three were bent over an angle of<br />

On-site propeller<br />

cropping in Ghent<br />

Permanent rudder repairs now<br />

possible <strong>with</strong>out drydocking<br />

Hydrex has developed an<br />

entirely new method enabling<br />

permanent repairs of rudders<br />

<strong>with</strong>out drydocking <strong>the</strong> ship. Permanent<br />

repairs were hi<strong>the</strong>rto not<br />

possible <strong>and</strong> ships had to drydock<br />

in case a major defect was found.<br />

The newly designed equipment is<br />

lightweight <strong>and</strong> can be mobilized<br />

very rapidly in our special flight<br />

containers. Therefore this new<br />

service is now available <strong>world</strong>wide.<br />

Major defects on rudders very often<br />

cause unscheduled drydocking of<br />

ships. The new method designed by<br />

our technical department allows<br />

engineers, welders <strong>and</strong> inspectors to<br />

perform <strong>the</strong>ir tasks in dry conditions.<br />

Class approved permanent repairs<br />

in-situ, <strong>with</strong>out moving <strong>the</strong> ship, are<br />

now possible <strong>and</strong> commercial operations<br />

can continue. Steel repairs <strong>and</strong><br />

replacements can be performed <strong>and</strong><br />

pintle <strong>and</strong> bushing defects can be<br />

solved <strong>with</strong>out <strong>the</strong> loss of time <strong>and</strong><br />

money associated <strong>with</strong> drydocking.<br />

The equipment can be mobilized <strong>with</strong>in<br />

hours to any port in <strong>the</strong> <strong>world</strong> <strong>and</strong> is<br />

available for rapid mobilization from<br />

<strong>the</strong> Hydrex headquarters in Antwerp.<br />

6<br />

The Hydrex team prepares for <strong>the</strong> propeller blade cropping.


A video inspection revealed severe damage to <strong>the</strong> propeller blades. Beside being bent, <strong>the</strong> propeller blades<br />

were also missing large chunks.<br />

Cropping <strong>the</strong> blades restored <strong>the</strong> propeller’s balance.<br />

All four blades of <strong>the</strong> propeller were cropped in <strong>the</strong> exact same manner.<br />

7<br />

90°. Because <strong>the</strong> damage was too<br />

extensive, straightening <strong>the</strong>se last<br />

three blades was not an option. To<br />

keep <strong>the</strong> balance of <strong>the</strong> propeller, it<br />

was decided to crop all four blades at<br />

<strong>the</strong> exact same position.<br />

The information acquired during<br />

<strong>the</strong> inspection was <strong>the</strong>n used to<br />

determine <strong>the</strong> correct measurements<br />

needed for <strong>the</strong> cropping. The area<br />

to be cropped was marked out on<br />

<strong>the</strong> four blades <strong>and</strong> verified. The<br />

team <strong>the</strong>n cropped <strong>the</strong> blades one by<br />

one <strong>and</strong> ground <strong>the</strong>ir edges to give<br />

<strong>the</strong>m <strong>the</strong> correct radius. When <strong>the</strong><br />

cropping was complete, <strong>the</strong> Hydrex<br />

technicians polished <strong>the</strong> blades to<br />

make sure that any remaining loss of<br />

efficiency would be minimal.<br />

This restored <strong>the</strong> propeller’s balance<br />

<strong>and</strong> brought its performance as close<br />

to its optimum performance as could<br />

be achieved. The job was completed<br />

on-site, saving <strong>the</strong> time, expense <strong>and</strong><br />

extra work of drydocking <strong>the</strong> vessel.<br />

KEEPING SHIPS<br />

IN BUSINESS<br />

KEEPING SHIPS


Underwater stern tube seal replacement<br />

on general cargo vessel in Las Palmas<br />

Last month Hydrex mobilized<br />

a diver/technician team to a<br />

145-meter general cargo vessel in<br />

Las Palmas, Spain when oil was<br />

leaking from <strong>the</strong> stern tube seal<br />

assembly of <strong>the</strong> ship. The team<br />

used <strong>the</strong> Hydrex flexible mobock<br />

technique to create a dry working<br />

environment <strong>around</strong> <strong>the</strong> assembly<br />

<strong>and</strong> replaced three damaged stern<br />

tube seals on-site, in drydock-like<br />

conditions.<br />

The operation started <strong>with</strong> a thorough<br />

underwater inspection of <strong>the</strong> stern<br />

tube seal assembly. This revealed that<br />

<strong>the</strong> rope guard was missing. The team<br />

also found a rope entangled <strong>around</strong><br />

<strong>the</strong> assembly, damaging <strong>the</strong> stern tube<br />

seals <strong>and</strong> causing <strong>the</strong> oil leak.<br />

The Hydrex flexible mobdock is used to create a dry working environment underwater.<br />

A rope was tangled <strong>around</strong> <strong>the</strong> stern tube seal assemby, damaging <strong>the</strong> seals.<br />

8<br />

Two of <strong>the</strong> split rings were <strong>the</strong>n<br />

disconnected <strong>and</strong> brought to <strong>the</strong><br />

surface to be cleaned. Next <strong>the</strong> diver/<br />

technicians installed <strong>the</strong> Hydrex<br />

flexible mobdock <strong>around</strong> <strong>the</strong> stern<br />

tube seal assembly. This allowed<br />

<strong>the</strong> team to work on <strong>the</strong> assembly<br />

in dry conditions, a necessity for<br />

permanent stern tube seal repairs.<br />

The divers <strong>the</strong>n replaced <strong>the</strong> three<br />

seals one by one <strong>with</strong> new ones.<br />

After <strong>the</strong>se were bonded, <strong>the</strong> team<br />

reassembled <strong>the</strong> entire unit <strong>and</strong><br />

pressure tests were carried out <strong>with</strong><br />

positive results. The flexible<br />

mobdock was <strong>the</strong>n removed, concluding<br />

<strong>the</strong> repair. Because a new<br />

rope guard could not be delivered<br />

on time, <strong>the</strong> ship superintendent<br />

decided to have it delivered to <strong>the</strong><br />

vessel’s next stop in Philadelphia,<br />

U.S.A.


Hydrex diver/technician working inside <strong>the</strong> flexible mobdock.<br />

After opening up <strong>the</strong> stern tube seal assembly, <strong>the</strong> divers could replace <strong>the</strong> seals.<br />

In order to provide <strong>the</strong> customer<br />

<strong>with</strong> <strong>the</strong> fastest possible response,<br />

flexibility was essential throughout<br />

<strong>the</strong> entire operation. Every day<br />

a ship has to go off hire causes a<br />

substantial loss of money. The team<br />

<strong>the</strong>refore worked in shifts to perform<br />

<strong>the</strong> stern tube seal repair <strong>with</strong>in<br />

<strong>the</strong> shortest possible time frame.<br />

Keeping his vessel out of drydock<br />

saved <strong>the</strong> customer a great deal of<br />

time <strong>and</strong> money.<br />

KEEPING SHIPS<br />

IN BUSINESS<br />

9 KEEPING SHIPS<br />

On-site bow<br />

thruster<br />

repairs<br />

The Hydrex lightweight flexible<br />

mobdocks are designed<br />

to be easily transported <strong>around</strong><br />

<strong>the</strong> <strong>world</strong> <strong>and</strong> are used to close<br />

off <strong>the</strong> thruster tunnel on both<br />

sides, allowing divers to perform<br />

repairs <strong>and</strong> o<strong>the</strong>r operations in<br />

a dry environment <strong>around</strong> <strong>the</strong><br />

bow thruster unit.<br />

This technique enables <strong>the</strong>m to<br />

reinstall <strong>the</strong> propeller blades of an<br />

overhauled thruster inside <strong>the</strong><br />

thruster tunnel after <strong>the</strong> unit has<br />

been secured or replace <strong>the</strong> blades<br />

or seals <strong>and</strong> perform repair work<br />

on a specific part <strong>with</strong>out removing<br />

<strong>the</strong> unit.<br />

Since <strong>the</strong> development of this<br />

flexible mobdock technique, nu-<br />

merous thruster repairs have been<br />

carried out by Hydrex diver/<br />

technicians <strong>around</strong> <strong>the</strong> <strong>world</strong>.<br />

There is no need to send <strong>the</strong><br />

vessel to drydock as all operations<br />

can be carried out in port or while<br />

<strong>the</strong> vessel is stationary at sea.<br />

Normal commercial activities<br />

can <strong>the</strong>refore continue <strong>with</strong>out<br />

disruption.<br />

Phone: + 32 3 213 5300 (24/7)<br />

Fax: + 32 3 213 5321<br />

hydrex@hydrex.be<br />

www.hydrex.be


<strong>Fast</strong> <strong>and</strong> <strong>easy</strong> <strong>Ecospeed</strong><br />

application offers many benefits<br />

for shipyards <strong>and</strong> shipowners<br />

Alot has been written on <strong>the</strong><br />

advantages of <strong>the</strong> <strong>Ecospeed</strong><br />

underwater ship hull coating<br />

system. The coating offers many<br />

long term benefits to shipowners,<br />

ship managers <strong>and</strong> operators <strong>and</strong><br />

this both from an economical as<br />

well as ecological point of view.<br />

The more practical <strong>and</strong> direct<br />

advantages of <strong>Ecospeed</strong> have been<br />

documented much less. In this<br />

article we take a closer look at how<br />

applying <strong>Ecospeed</strong> to a vessel can<br />

save much worry, time <strong>and</strong> hassle<br />

for superintendents <strong>and</strong> shipyards<br />

during drydockings, as well as<br />

save expenses for <strong>the</strong> owner.<br />

Despite some supplier claims to <strong>the</strong><br />

contrary, almost no underwater hull<br />

coating provides for <strong>the</strong> most basic<br />

objective which is to protect <strong>the</strong> steel<br />

from corrosion <strong>and</strong> prevent <strong>the</strong> hull<br />

from ‘roughening’ <strong>with</strong> age. When<br />

ships come into drydock, it is not<br />

uncommon to observe delamination<br />

of multiple paint layers. There is<br />

often also evidence of corrosion<br />

<strong>and</strong> hull roughening. Repairs of <strong>the</strong><br />

underwater hull coating systems<br />

With <strong>Ecospeed</strong> no full repaint will be necessary during future drydockings.<br />

12<br />

An <strong>Ecospeed</strong> application is adapted to a ship yard’s schedule.<br />

greater than 50 percent of <strong>the</strong><br />

underwater area, <strong>and</strong> up to <strong>and</strong><br />

including complete replacement of<br />

<strong>the</strong> hull coating, are not uncommon.<br />

This results in significant cost to<br />

<strong>the</strong> shipowners, both in terms of<br />

materials <strong>and</strong> labor, <strong>and</strong> in fuel costs<br />

due to <strong>the</strong> roughened conditions<br />

of <strong>the</strong> hulls <strong>and</strong> ultimately also in<br />

frequent required drydocking-time.<br />

So it’s <strong>easy</strong> to see that <strong>the</strong> total<br />

ownership cost (TOC) of a vessel<br />

would drop for a ship operating <strong>with</strong><br />

a hull that is effectively protected.<br />

<strong>Ecospeed</strong> is an extremely hard<br />

coating <strong>with</strong> optimized hydrodynamics<br />

that can easily be maintained<br />

in service. This has a huge potential<br />

for reducing total cost of ownership<br />

of <strong>the</strong> vessel. When ships come out of<br />

<strong>the</strong> water after lengthy periods, <strong>the</strong>re<br />

is no delamination of <strong>the</strong> coating<br />

from <strong>the</strong> hull, <strong>the</strong>re are no paint<br />

blisters that would be indicative of


<strong>Ecospeed</strong> also protects areas that are more prone to cavitation damage, like<br />

rudders.<br />

anti-corrosive failure, <strong>and</strong> <strong>the</strong> overall<br />

hull is still smooth. There are<br />

also <strong>the</strong> environmentally friendly<br />

aspects of <strong>the</strong> product. Studies done<br />

in <strong>the</strong> EU, by <strong>the</strong> Ne<strong>the</strong>rl<strong>and</strong>s in<br />

particular, have determined that in-<br />

water cleaning of <strong>Ecospeed</strong> pro-<br />

duces no materials that are toxic<br />

to <strong>the</strong> marine environment.<br />

High quality application–<br />

<strong>the</strong> secret of long term<br />

durability<br />

The reason for <strong>the</strong> pristine condition<br />

of <strong>the</strong> <strong>Ecospeed</strong> coating after several<br />

service years is very simple according<br />

to Mr. Gunnar Ackx, managing<br />

director of SCICON Worldwide,<br />

After surface preparation, <strong>Ecospeed</strong> is applied in only two, identical, coats.<br />

13<br />

an independent coating inspection<br />

<strong>and</strong> consulting company. SCICON<br />

provides clients <strong>with</strong> various in-<br />

spection <strong>and</strong> consulting services in<br />

<strong>the</strong> field of corrosion protection of<br />

steel, concrete, <strong>and</strong> o<strong>the</strong>r surfaces in<br />

just about any industry. SCICON’s<br />

main focus is Europe, but <strong>the</strong>y have<br />

clients in many countries <strong>around</strong> <strong>the</strong><br />

<strong>world</strong>.<br />

As a coating inspector <strong>and</strong> consultant,<br />

Gunnar Ackx has had <strong>the</strong><br />

opportunity to inspect <strong>and</strong> assist<br />

<strong>the</strong> very first <strong>Ecospeed</strong> application,<br />

almost ten years ago. “When I first<br />

saw <strong>the</strong> ship come out of <strong>the</strong> water<br />

prior to <strong>the</strong> <strong>Ecospeed</strong> application<br />

<strong>and</strong> noticed how banged up <strong>the</strong> hull<br />

was, my first reaction was: ‘This<br />

is never going to work.’ But that<br />

job certainly did prove me wrong.<br />

I have been amazed at <strong>Ecospeed</strong>’s<br />

performance ever since.”<br />

To Mr. Ackx it is clear that <strong>the</strong> high<br />

quality of an <strong>Ecospeed</strong> application is<br />

key to <strong>the</strong> excellent results obtained<br />

<strong>with</strong> <strong>the</strong> coating. “An SSPC-SP10 /<br />

ISO Sa 2.5 blast cleanliness is still<br />

<strong>the</strong> best value for money in <strong>the</strong><br />

corrosion protection business, irrespective<br />

of <strong>the</strong> type of coating<br />

project,” he says. “We always advocate<br />

that surface preparation is <strong>the</strong><br />

foundation of any coating system. So<br />

as soon as you start tampering <strong>with</strong><br />

<strong>the</strong> quality of <strong>the</strong> surface preparation,<br />

you will tamper <strong>with</strong> <strong>the</strong> total<br />

quality, hence service life of ANY


An <strong>Ecospeed</strong> coating inspector is present <strong>and</strong> available<br />

for <strong>the</strong> painters on every job.<br />

coating. A proverb that we often use<br />

during our inspection assignments<br />

is: ‘If you fail to prepare, prepare<br />

to fail’ which says a lot about <strong>the</strong><br />

above. Of course an SSPC-SP10 /<br />

ISO Sa 2.5 blast cleanliness is not<br />

<strong>the</strong> cheapest of surface preparations<br />

you can get <strong>and</strong> can sometimes be<br />

somewhat challenging in a drydocking<br />

situation. However, you<br />

will only have to do it once! Because<br />

once you have applied <strong>the</strong> 2-coat<br />

<strong>Ecospeed</strong> hull coating, you’ll never<br />

have to reblast again, throughout <strong>the</strong><br />

entire service life of <strong>the</strong> ship.”<br />

The importance of a quality st<strong>and</strong>ard<br />

during application cannot be<br />

overestimated. <strong>Ecospeed</strong>’s manu-<br />

facturers have access to very ex-<br />

14<br />

tensive research in this field <strong>and</strong><br />

especially regarding <strong>the</strong> decay or<br />

degradation of o<strong>the</strong>r paint systems<br />

over drydocking intervals. Most of<br />

<strong>the</strong> time <strong>the</strong> effect of this degradation<br />

of <strong>the</strong> paint system <strong>and</strong> <strong>the</strong> build up<br />

of paint layers on <strong>the</strong> fuel efficiency<br />

of <strong>the</strong> ship has been largely underestimated.<br />

Ideally, during a second<br />

special survey of a ship in drydock<br />

Class Accepted underwater stern<br />

tube seal repairs under warranty<br />

Using our flexible mobdock<br />

method to create a dry underwater<br />

environment, we have carried<br />

out stern tube seal repairs <strong>and</strong><br />

replacements underwater for some<br />

years now in cooperation <strong>with</strong> top<br />

specialist suppliers.<br />

This technology brings drydock<br />

conditions to <strong>the</strong> ship ra<strong>the</strong>r than<br />

having to take <strong>the</strong> ship to drydock,<br />

saving a considerable amount of<br />

time <strong>and</strong> money in doing so.<br />

This class accepted method is<br />

performed by our diving teams under<br />

our warranty. It can be used while <strong>the</strong><br />

ship is carrying out its usual cargo or<br />

o<strong>the</strong>r commercial operations in port.<br />

Visit <strong>the</strong> special stern tube seal repair<br />

section on our website for more<br />

information <strong>and</strong> examples of <strong>the</strong><br />

many seal repairs we have performed<br />

in recent years.<br />

www.hydrex.be<br />

The second (final) coat can be applied <strong>with</strong>in a couple of<br />

hours or after a few weeks or even months.


By removing <strong>the</strong> existing paint layers <strong>and</strong> applying<br />

<strong>Ecospeed</strong> on rudders we can break <strong>the</strong> never ending cycle<br />

of painting <strong>and</strong> repainting.<br />

<strong>Ecospeed</strong>’s flexibility enables absorption<br />

of <strong>the</strong> forces that are produced<br />

by cavitation, preventing damage.<br />

<strong>the</strong>re are very substantial benefits<br />

in stripping away all <strong>the</strong> old paint;<br />

immediate fuel savings of up to<br />

20-30% are very realistic numbers.<br />

When <strong>the</strong> <strong>Ecospeed</strong> coating is<br />

applied correctly this build up of<br />

paint layers is ended forever. Any<br />

paint system is only as good as it<br />

is applied. For this reason at least<br />

one <strong>Ecospeed</strong> coating inspector is<br />

present <strong>and</strong> available for <strong>the</strong> painters<br />

on every job. This is to check <strong>the</strong><br />

conditions during <strong>the</strong> application<br />

process, but also to work closely<br />

<strong>with</strong> <strong>the</strong>m to help ensure a very <strong>easy</strong><br />

<strong>and</strong> smooth application. Because <strong>the</strong><br />

inspectors are closely involved <strong>with</strong><br />

<strong>the</strong> application, <strong>the</strong>y know exactly<br />

what has happened during <strong>the</strong><br />

coating process. This allows <strong>the</strong>m<br />

to approve <strong>the</strong> 10 year warranty that<br />

comes <strong>with</strong> an <strong>Ecospeed</strong> application.<br />

Hydrex works <strong>with</strong> its own team<br />

of highly certified, highly qualified<br />

coating inspectors. These inspectors<br />

have been working <strong>with</strong> <strong>Ecospeed</strong><br />

for many years. They are not only<br />

familiar <strong>with</strong> <strong>Ecospeed</strong>, but <strong>with</strong><br />

a wide variety of o<strong>the</strong>r coating<br />

systems. They are also very important<br />

in terms of cooperation<br />

<strong>with</strong> <strong>the</strong> shipyard, making sure that<br />

<strong>the</strong> product is applied according<br />

to <strong>the</strong> required st<strong>and</strong>ards <strong>and</strong> thus<br />

15<br />

Shipowners will not have to do any repainting beyond<br />

minor touch-ups during future drydockings.<br />

The coating can also be used to protect thruster tunnels against cavitation <strong>and</strong><br />

corrosion damage.<br />

that <strong>the</strong> results will be <strong>the</strong>re for <strong>the</strong><br />

shipowner for <strong>the</strong> next ten years <strong>and</strong><br />

beyond.<br />

Cost of application <strong>and</strong><br />

maintenance in relation to<br />

total ownership cost<br />

If an owner really has problems <strong>with</strong><br />

<strong>the</strong> cost of such surface preparation,<br />

Gunnar usually sits down <strong>with</strong> <strong>the</strong>m<br />

to do <strong>the</strong> math on <strong>the</strong> alternatives.<br />

“If you reapply 2, 3 to 4 layers of<br />

antifouling coating on <strong>the</strong> entire<br />

hull <strong>and</strong> are re-doing <strong>the</strong> above<br />

every 3 to 5 years, you inevitably<br />

come to a point where <strong>the</strong>re are too<br />

many layers of coating on <strong>the</strong> ship’s


hull.” Gunnar <strong>the</strong>n tells <strong>the</strong>m that,<br />

“This will degrade <strong>the</strong> quality of <strong>the</strong><br />

coating even more easily <strong>and</strong> rapidly<br />

because of <strong>the</strong> internal stresses being<br />

built up in <strong>the</strong> coating, resulting in a<br />

required full reblast, probably every<br />

10 years or so.” He recalls a recent<br />

drydocking of a large cruise vessel<br />

where some 2.0 to 2.5 mm thick<br />

old coating system was removed<br />

completely. “It probably consisted<br />

of up to 15 or more layers, which<br />

were continuously flaking off here<br />

<strong>and</strong> <strong>the</strong>re <strong>and</strong> were patch-repaired<br />

for a number of years. If you make<br />

such a calculation over, say, a 25year<br />

service life <strong>and</strong> compare that<br />

<strong>with</strong> <strong>the</strong> initial cost of <strong>the</strong> <strong>Ecospeed</strong><br />

application combined <strong>with</strong> <strong>the</strong> very<br />

minimal maintenance it requires, it<br />

doesn’t take a rocket scientist to figure<br />

out which is more economical. And<br />

that is not even taking into account<br />

possible reduced drydocking times<br />

<strong>and</strong> fuel savings because of some<br />

o<strong>the</strong>r characteristics of <strong>the</strong> <strong>Ecospeed</strong><br />

hull coating.”<br />

Flexible <strong>and</strong> <strong>easy</strong> to learn<br />

application process<br />

The high st<strong>and</strong>ard that Hydrex<br />

dem<strong>and</strong>s for an <strong>Ecospeed</strong> application<br />

does not mean that learning to work<br />

<strong>with</strong> <strong>the</strong> coating is a difficult process<br />

nor that <strong>the</strong> application itself is hard<br />

to schedule or carry out.<br />

Applying <strong>Ecospeed</strong> is quite straightforward.<br />

Common sense needs to<br />

be used <strong>with</strong> every single coating<br />

application. There are stricter guide-<br />

lines on <strong>the</strong> pot life <strong>and</strong> <strong>the</strong> thorough<br />

cleaning of equipment, but in general<br />

it paints like any o<strong>the</strong>r paint. Most<br />

applicators are quite familiar <strong>with</strong><br />

hard solid paints <strong>and</strong> <strong>the</strong>y know <strong>the</strong><br />

tricks of <strong>the</strong> trade. Mr. Ackx confirms<br />

this. “In <strong>the</strong> last couple of years our<br />

inspectors have probably inspected<br />

close to 125 <strong>Ecospeed</strong> <strong>jobs</strong> <strong>and</strong><br />

every time <strong>the</strong> specifications were<br />

followed by <strong>the</strong> coating contractor,<br />

<strong>the</strong> application went very well <strong>and</strong><br />

smoothly.”<br />

The <strong>Ecospeed</strong> coating also offers a<br />

tremendous flexibility to <strong>the</strong> shipyard.<br />

The minimum overcoating<br />

time is three to four hours, which<br />

means that, for smaller surfaces<br />

such as rudders, propellers or bow<br />

thrusters, <strong>the</strong> two coats required<br />

can often be applied in one single<br />

day. “If blasting is done overnight<br />

<strong>and</strong> approved during a morning<br />

inspection, <strong>the</strong> object to be coated<br />

can be ready by nightfall.” Mr. Ackx<br />

tell us. “As <strong>the</strong> coating inspector,<br />

you rarely come in at <strong>the</strong> exact right<br />

time when <strong>the</strong> yard is ready to start<br />

blasting <strong>and</strong>/or coating. Especially<br />

during drydockings, <strong>the</strong>re is a lot<br />

more going on than just <strong>the</strong> hull<br />

16<br />

coating, which can easily interfere<br />

<strong>with</strong> <strong>the</strong> planning of your project.<br />

Because of <strong>the</strong> fact that <strong>Ecospeed</strong><br />

consists of only 2 coats <strong>and</strong> has<br />

quick <strong>and</strong> flexible overcoating<br />

times, this often allows <strong>the</strong> <strong>Ecospeed</strong><br />

job to be scheduled <strong>around</strong> o<strong>the</strong>r<br />

work taking place, resulting in<br />

minimal interference among various<br />

activities.” He recalls a drydocking<br />

in Malaysia, where <strong>the</strong> wea<strong>the</strong>r is<br />

notoriously unpredictable: “They<br />

were applying <strong>Ecospeed</strong> onto <strong>the</strong><br />

vertical sides of a ship <strong>with</strong> steel<br />

temperatures up to 39 °C because<br />

of <strong>the</strong> sun when five minutes later a<br />

thunderstorm passed by <strong>and</strong> chased<br />

everyone underneath <strong>the</strong> ship. After<br />

<strong>the</strong> storm had passed, I expected<br />

<strong>the</strong> coating to have sustained quite<br />

some rain impact damage, but to<br />

my surprise <strong>the</strong> coating was curing<br />

so rapidly on <strong>the</strong> hot steel surface<br />

A two coat application is always going to be quicker, cheaper <strong>and</strong> more flexible<br />

compared to o<strong>the</strong>r systems.


The high st<strong>and</strong>ard that Hydrex dem<strong>and</strong>s for an <strong>Ecospeed</strong> application does not<br />

mean that learning to work <strong>with</strong> <strong>the</strong> coating is a difficult process.<br />

that absolutely no rain damage was<br />

visible at all. There were also no<br />

signs of ‘solvent-entrapment’ whatsoever,<br />

which sometimes occurs<br />

when solvent based coatings are<br />

applied onto too hot of a surface.<br />

Twenty minutes later <strong>the</strong> hull had<br />

dried up <strong>and</strong> we could continue<br />

spraying again.”<br />

<strong>Ecospeed</strong> only requires two layers<br />

of 500 µm each. This is also a major<br />

advantage compared <strong>with</strong> o<strong>the</strong>r hull<br />

coatings. “Whe<strong>the</strong>r you’re looking at<br />

classic antifouling coating systems<br />

which easily have five or more<br />

coating layers to be applied, or when<br />

comparing <strong>Ecospeed</strong> to some of <strong>the</strong><br />

newer silicone based hull coatings,<br />

which also consist of four to five<br />

layers of coating to be applied, a<br />

two coat application is always going<br />

to be quicker, cheaper <strong>and</strong> more<br />

flexible,” Gunnar Ackx explains.<br />

The coating schedule can be adapted<br />

to that of <strong>the</strong> yard <strong>and</strong> it does not<br />

have to be <strong>the</strong> o<strong>the</strong>r way <strong>around</strong>. A<br />

traditional paint application schedule<br />

is defined by surface preparation <strong>and</strong><br />

by <strong>the</strong> wea<strong>the</strong>r conditions, which are<br />

difficult to predict. In this respect <strong>the</strong><br />

application of <strong>Ecospeed</strong> is easier to<br />

adapt to <strong>the</strong> application windows that<br />

become available. You can apply <strong>the</strong><br />

coating quite rapidly on a prepared<br />

surface <strong>and</strong> <strong>the</strong> possible overcoat<br />

time ranges from three hours to very<br />

extended periods of time. Depending<br />

on whatever suits <strong>the</strong> owners’ or<br />

<strong>the</strong> shipyard’s schedule <strong>the</strong> second<br />

(final) coat can be applied <strong>with</strong>in a<br />

couple of hours or after a few weeks<br />

or even months.<br />

Easier to plan drydockings<br />

for <strong>the</strong> rest of <strong>the</strong> vessel’s<br />

service life<br />

The durability of <strong>Ecospeed</strong> makes<br />

<strong>the</strong> planning of future drydockings<br />

far easier for <strong>the</strong> shipowner <strong>and</strong><br />

<strong>the</strong> shipyard. Shipowners will not<br />

have to do any repainting beyond<br />

17<br />

minor touch-ups, if needed. These<br />

can easily be done during a short<br />

drydock visit, which is in contrast to<br />

<strong>the</strong> full renewal of paint layers that<br />

is needed <strong>with</strong> o<strong>the</strong>r paint systems.<br />

<strong>Ecospeed</strong> is a coating system that<br />

lasts <strong>the</strong> lifetime of <strong>the</strong> vessel; <strong>the</strong><br />

initial application is <strong>the</strong>refore critical<br />

for <strong>the</strong> success of <strong>the</strong> coating.<br />

Mr. Ackx confirms that if a ship<br />

coated <strong>with</strong> <strong>Ecospeed</strong> comes into<br />

drydock after some years of service,<br />

<strong>the</strong> planning of this docking is so<br />

much simpler than <strong>with</strong> vessels<br />

coated <strong>with</strong> o<strong>the</strong>r underwater hull<br />

paint systems. “I have had <strong>the</strong> op-<br />

portunity of witnessing <strong>the</strong> drydocking<br />

of a number of vessels, <strong>with</strong><br />

different types of hull coatings. With<br />

classic antifoulings, most people in<br />

<strong>the</strong> shipping industry know what’s<br />

happening: <strong>the</strong> antifouling has to be<br />

renewed every three to five years,<br />

maximum, during which <strong>the</strong>re will<br />

also easily be five, ten or more<br />

percent of corrosion present on <strong>the</strong><br />

underwater hull, which requires spot<br />

blasting <strong>and</strong> touch-up as well. After<br />

a couple of recoating cycles, <strong>the</strong><br />

total coating system becomes<br />

increasingly weaker, resulting in<br />

more repairs <strong>and</strong> maintenance<br />

that needs to be done <strong>with</strong> every<br />

drydocking <strong>and</strong> this up to <strong>the</strong> point<br />

where <strong>the</strong> entire underwater hull<br />

needs to be fully reblasted.”<br />

Mr. Ackx says that <strong>the</strong> newer<br />

hull coatings such as silicone<br />

based coatings provide for better<br />

performance in that department,<br />

but also come <strong>with</strong> a higher initial<br />

installation cost. “Having seen a<br />

silicone based antifouling on a ship<br />

that was drydocked after some three<br />

years of service, I must admit that<br />

<strong>the</strong> hull looked very good <strong>and</strong> could<br />

be cleaned quite easily. The problem<br />

is that such a coating is soft <strong>and</strong> has<br />

relatively limited thickness. Hence


<strong>the</strong>re was quite some mechanical<br />

damage all <strong>the</strong> way through <strong>the</strong><br />

coating, down to <strong>the</strong> steel, resulting<br />

in hull corrosion.” He compares this<br />

to an <strong>Ecospeed</strong> hull coating coming<br />

in for drydocking. “You see that <strong>the</strong><br />

damage is so limited on an <strong>Ecospeed</strong><br />

hull coating that it can easily be<br />

seen, which makes it easier to repair<br />

<strong>and</strong> to maintain. During <strong>the</strong> recent<br />

drydocking of a large, <strong>Ecospeed</strong><br />

coated cruise vessel which had run<br />

aground, resulting in <strong>the</strong> buckling of<br />

some 40 meters of bottom plate, only<br />

a very limited number of scratches<br />

down to <strong>the</strong> substrate were observed.<br />

On 90% of <strong>the</strong> 40 m² affected,<br />

<strong>Ecospeed</strong> only showed superficial<br />

scratches <strong>and</strong> still adhered perfectly<br />

to <strong>the</strong> steel. The high adhesion of <strong>the</strong><br />

<strong>Ecospeed</strong> coating to <strong>the</strong> steel actually<br />

also helps to reduce any undercreep<br />

corrosion, which <strong>with</strong> <strong>the</strong> traditional<br />

coating systems is responsible for<br />

<strong>the</strong> exponential expansion of <strong>the</strong><br />

coating damage.”<br />

The amount of time many ships<br />

spend in drydock is directly related<br />

to (re)painting <strong>the</strong> underwater hull.<br />

When repainting <strong>the</strong> underwater hull<br />

can be taken out of <strong>the</strong> equation for<br />

<strong>the</strong> choice of location <strong>and</strong> season for<br />

drydocking, <strong>the</strong>n <strong>the</strong> story becomes a<br />

lot easier for superintendents, for <strong>the</strong><br />

shipyards, for everybody involved.<br />

Easy <strong>and</strong> environmentally<br />

friendly fouling removal<br />

The st<strong>and</strong>ard procedure for shipyards<br />

when a ship enters drydock is a<br />

general wash down of <strong>the</strong> ship<br />

hull to clear away any fouling <strong>and</strong><br />

residues, especially salt residues that<br />

may adhere to <strong>the</strong> coating system.<br />

With <strong>Ecospeed</strong> <strong>the</strong> coating is always<br />

in a br<strong>and</strong> new, excellent condition<br />

after <strong>the</strong> high pressure washing.<br />

The surface texture is very smooth.<br />

The high pressure washing reveals<br />

<strong>with</strong>out exception that <strong>Ecospeed</strong><br />

does not need any additional paint<br />

layers. There is also a very big<br />

18<br />

difference between cleaning <strong>Ecospeed</strong><br />

<strong>and</strong> o<strong>the</strong>r paints. When washing<br />

an antifouling paint in drydock,<br />

everything on <strong>the</strong> bottom of <strong>the</strong><br />

drydock is discolored <strong>with</strong> dirty red<br />

water filled <strong>with</strong> toxins, <strong>and</strong> <strong>the</strong> antifouling<br />

paint spreads everywhere on<br />

<strong>the</strong> bottom of <strong>the</strong> drydock. With<br />

<strong>Ecospeed</strong>, none of <strong>the</strong> paint material<br />

is lost. It’s clean water that you see.<br />

Only <strong>the</strong> fouling is removed. The<br />

coating stays on <strong>the</strong> ship instead<br />

of dispersing in <strong>the</strong> water <strong>and</strong> contaminating<br />

<strong>the</strong> shipyard <strong>and</strong> <strong>the</strong><br />

surrounding waters.<br />

Summary<br />

We hope that this article has<br />

helped communicate <strong>the</strong> practical<br />

aspects of applying <strong>Ecospeed</strong>, <strong>the</strong><br />

differences between <strong>Ecospeed</strong> <strong>and</strong><br />

o<strong>the</strong>r underwater hull coatings, <strong>and</strong><br />

<strong>the</strong> low cost-to-savings ratio that<br />

can be obtained by using <strong>Ecospeed</strong><br />

to protect <strong>the</strong> underwater hull of any<br />

vessel afloat today.<br />

<strong>Ecospeed</strong> can be cleaned underwater or <strong>with</strong> high pressure tools in drydock <strong>with</strong>out damaging <strong>the</strong> coating.


Hydrex has certified divers at its disposal, ready<br />

to perform all types of offshore inspections.<br />

Fully trained <strong>and</strong> certified diver/technicians<br />

Removal of heavy marine fouling<br />

on FPSO <strong>and</strong> drill vessels<br />

Turnkey underwater solutions for <strong>the</strong> offshore industry<br />

19<br />

31<br />

Underwater solutions<br />

avoid drydocking<br />

<strong>Fast</strong> response centers <strong>with</strong><br />

instant mobilizable equipment<br />

Phone: +32 3 213 5300 (24/7)<br />

Fax: +32 3 213 5321<br />

E-mail: hydrex@hydrex.be<br />

www.hydrex.be


Hydrex offers turnkey underwater<br />

repair solutions to shipowners<br />

wherever <strong>and</strong> whenever<br />

<strong>the</strong>y are needed. Hydrex’s multidisciplinary<br />

team will help you find<br />

<strong>the</strong> best solution for any problem<br />

encountered <strong>with</strong> your ship below<br />

<strong>the</strong> water line. We will immediately<br />

mobilize our diver/technicians to<br />

carry out necessary repair work<br />

<strong>with</strong>out <strong>the</strong> need to drydock.<br />

Hydrex has a long track record of<br />

Headquarters Hydrex N.V. - Antwerp<br />

Phone: + 32 3 213 5300 (24/7)<br />

E-mail: hydrex@hydrex.be<br />

Hydrex Spain - Algeciras<br />

Phone: + 34 (956) 675 049 (24/7)<br />

E-mail: info@hydrex.es<br />

<strong>Fast</strong> underwater repairs<br />

keep ships out of drydock<br />

performing complex permanent underwater<br />

repairs to thrusters, propellers,<br />

rudders, stern tube seals <strong>and</strong> damaged<br />

or corroded hulls. By creating<br />

drydock-like conditions <strong>around</strong> <strong>the</strong><br />

affected area, our diver/technicians<br />

can carry out <strong>the</strong>se operations in port<br />

or at anchor.<br />

All <strong>the</strong> projects we undertake are<br />

engineered <strong>and</strong> carried out in close<br />

cooperation <strong>with</strong> <strong>the</strong> customer <strong>and</strong><br />

any third party suppliers, relieving<br />

Hydrex LLC - Tampa, U.S.A.<br />

Phone: + 1 727 443 3900 (24/7)<br />

E-mail: info@hydrex.us<br />

Hydrex West Africa – Port Gentil, Gabon<br />

Phone: + 241 04 16 49 48 (24/7)<br />

E-mail: westafrica@hydrex.be<br />

www.hydrex.be<br />

<strong>the</strong> customer of all <strong>the</strong> hassle of coordination,<br />

planning <strong>and</strong> supervision.<br />

Headquartered in <strong>the</strong> Belgian port of<br />

Antwerp, we have offices in Tampa<br />

(U.S.A), Algeciras (Spain), Mumbai<br />

<strong>and</strong> Visakhapatnam (India), <strong>and</strong> Port<br />

Gentil (Gabon).<br />

All Hydrex offices have fully operational<br />

fast response centers where an<br />

extensive range of state-of-<strong>the</strong>-art<br />

equipment is available at all times.<br />

Hydrex India - Mumbai<br />

Phone: + 91 222 2046 988 (24/7)<br />

E-mail: mumbai@hydrex.be<br />

Hydrex India -Vishakhapatnam<br />

Phone: + 91 891 2711 863 (24/7)<br />

E-mail: vishakhapatnam@hydrex.be

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