DISCOVERER II
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The 70 metre LOA, Research Vessel Discoverer II also dry-docked with Babcock in April 2008. The 2,722 GRT Seismic Research vessel operated by Seabird Exploration had completed a survey program in NZ waters and was due for dry-dock repairs prior to the next assignment in SE Asia.
The Discoverer initially arrived at VTF's repair berth for 2 days for removal of high value survey equipment and towed array systems and then moved to dry-dock.
The key reft items were the overhaul of the vessels two Worthington 5 – stage seismic survey air compressors together with their ALCO 12-251-C diesel engines and removal for survey of the twin rudders and tail shafts.
The extensive work package also included; overhaul of 2 in no. 650 kVA caterpillar alternators, rewinding four 8.5 kW engine room and compressor room ventilation fan motors, installation of additional tank manholes and repairs to service tanks.
Also included was manufacture of navigation equipment foundations and overhaul of hydraulic mooring winch controls and shaft bushes. Deck works included overhaul of deck cranes, installation of a fre fghting foam system, modifcation to potable water systems and changing location of life rafts. Preservation works included painting of underwater hull and fresh water tanks.
Overall, more than 10,000 hours of work was completed in the 25 day repair period, including 2 weeks in dry-dock. The Owners representative commented that it had been a successful docking and repair period, and was pleased with the volume of work completed in the time available.
TRIPLE DOCKING
In August, VTF dry-docked 3 smaller local vessels together, including the 38 metre LOA Steam Tug William C Daldy, an NZ Navy Barge and a local Split Hopper Barge, Sound Cem 1.
The critical work package was for the Sound Cem 1 which required renewal of 150 sqm of bottom shell plating and stiffeners as well as preservation of external hull and internal tanks and void spaces.
The old steam tug Daldy also required a fair amount of work in the way of renovation of the foredeck area, removal of the deck fttings, windlass etc, renewal of deck timber, partial re-plating of deck house connections and renewal of deck scuppers and ventilation fttings.
Blasting and painting of the underwater hull and topsides as well as shell plating repairs were also required.
In fact, this unlikely combination of vessels worked very well in that we were able to provide a cost effective drydock solution for these smaller vessels, whilst keeping VTF workshops fully utilized.
JACQUES CARTIER
The French Navy's Light Transport Ship Jacques Cartier arrived in Auckland in September 2008 to undertake a dry-docking and mid life reft. The Jacques Cartier is an 80 metre LOA, 1,330 tonnes Light Transport Ship built in 1983 and is one of fve French Navy vessels based in New Caledonia.
This project involved approximately 40,000 repair man hours for Babcock workshops and allied subcontractors with key items including overhaul of the full propulsion train including main engines, gear box and shaft lines with KaMeWa pitch control systems.
Also overhaul of auxiliary diesel generators, overhaul of ship refrigeration and air conditioning services as well as freshwater, sea water and sewage systems. To reduce confict for working space in the vessels compact machinery spaces, shipping routes were cropped in the main machinery space side shell so that main and auxiliary engines, alternators and associated equipment could be removed to VTF workshops for overhaul.
Overhauls were also carried out on deck equipment, including cranes, mooring winches and capstans. Paint systems were renewed on external hull and some decks, as well as cargo ramps, bow access doors and tank spaces. The bow doors and bow ramps being a key part of the vessels operational requirement to launch and retrieve vehicles from improvised landing areas, required extensive repair works including machining and re-alignment of doors, general steelwork repairs and servicing and calibration of proximity switches and hydraulic systems. Further emergent work included shell and structural repairs resulting from hull surveys.
This contract is a milestone for VTF in that, this is the frst time that a Foreign Navy vessel has been commercially reftted at Devonport Dockyard. VTF were contracted for the work to DCNS, a major French Defense Contractor. VTF had previously worked with DCNS in 2007 to bid for the Reft of the French Navy Frigate Vendemiaire, also based in the South West Pacifc. In that instance we came a very close second to the selected Singapore Shipyard.
We were therefore very pleased to win the Jacques Cartier contract against International competition. Although the contracting process was complex, the co-operation with the French Navy Offcers and Crew was excellent and despite the challenging documentation, the project went well with the project including commissioning and trials completed in 12.5 weeks.
LPG CARRIER BOUGAINVILLE
The 100 metre LOA, 4,867t DWT Liquefed Gas Carrier Bougainville dry-docked with VTF in February 2009 for underwater and topsides hull preservation and general underwater and machinery survey items.
Other work included cleaning and servicing of the auxiliary boiler and exhaust gas economizer, survey of sea valves and anchor cables and miscellaneous repairs. Although not a large work package, this was an important docking for VTF, in that it was the frst docking at Devonport Dockyard for the Australia based Ship Managers Oceangas and also, the frst LPG Carrier to be dry-docked at the yard. It nearly didn't proceed due to a bottleneck of dry-dock projects around the originally planned October 2008 docking date, however with co-operation by the Ship Managers, we were able to re-schedule the docking for early this year.
DECEMBER CRUISE SHIPS
December 2008 was a busy period with the 103 metre LOA Cruise Ship, Clipper Odyssey dry-docking on 26 November for NKK survey and hull preservation. The 63 metre Australian owned expedition style cruise vessel Oceanic Discoverer arrived on 1 December, to dock on completion of the Clipper Odyssey.
VTF have docked the Clipper Odyssey before, but this was our frst project for the vessel under the new managers International Shipping-Miami. The Clipper Odyssey dry-docking work package which was limited to underwater hull and topsides water blasting and painting, survey of sea valves and underwater fttings and miscellaneous repairs, went well with the Clipper Odyssey in dock for only 10 days.
The Oceanic Discoverer was a much bigger work package and one of the most interesting and challenging projects of the year. It involved the retroft of a pair of Rolls Royce Aquarius 50 retractable fn stabilizers, which were delivered to VTF in a modular form complete with a hull plate section. The hull plate sections complete with modules were to be inserted into shell openings to be cut by the yard in an existing void compartment. Being a retro-ft, things were not at all straight forward. In order to avoid signifcant modifcation to the deck overhead, the design required that the stabiliser fn modules to be positioned with the lower section of the module exceeded the existing hull profle. The manufacture of a series of fairing plates was therefore required to create a blister effect for each housing.
Other work required for the installation included ftting new hydraulic power units and systems as well as cooling pipe work and electrical power and control cabling. Whilst in dock the vessel also underwent hull painting, survey and general maintenance.
CAPITAINE WALLIS
The 5650 DWT Multi – Purpose Container Vessel Capitaine Wallis entered dry dock, as scheduled on New Years Eve morning.
The repair package included items due for survey and Class renewal such as anchor cables and underwater valves, several of which required considerable restoration work to return to reliable service. Stern tube seals and propeller blade seals were renewed, underwater hull and topsides preparation and painting was carried out (the vessel looking smart with new “Cornflower Blue” topsides).
However the main event was to crop out and renew approx 8 tonnes of keel and shell plating resulting from pounding damage. Once the dock was dry and the damage inspected, it became apparent that a significantly larger area of shell plating than planned needed to be replaced, some 14 Tonnes in fact, as well as associated frames.
The vessel undocked on Monday the 21st January, a mere two days shift in schedule. Unfortunately with Commercial vessel repair it is often difficult for members of a successful team, such as this one, to get a sense of the impact that their labours have on other stakeholders – in this case our customer Neptune Shipping. Suffice to say that the owners representative who was here on site has remarked that Neptune Shipping are very pleased with the outcome, satisfied that Babcock has contained the emergent work with the least possible disruption to their trading schedule.
DISCOVERY 2
What started out as a big package in a short time, ended up as an even greater package that still needed to be completed within the same timeframe. Some of the larger jobs completed included;
- Fitting an additional A/C compressor and condenser for the accommodation,
- Overhauling two V12 ALCO diesel engines and substantial repair work on the two Worthington 5 - stage air compressors that they drive,
- Overhauling two 650KVa Caterpillar alternators,
- Rewinding four 8.5Kw engine room and compressor room ventilation fan motors.
- Hull treatment including blasting and painting U/W Hull, Topsides and Superstructure,
- Changing the location of the Life rafts,
- Removal of tail shafts, rudders and rudder stocks,
- The modification of F/W tanks to comply with access Regulations.
Overall, more than 9,000 hours of work was completed in the 25 day repair period.
The Owners representative commented that it had been a successful docking and repair period, and was pleased with the volume of work completed in such a condensed time frame.
SARA THERESA
The Sara Theresa came into dock to complete a 5 year special survey and some additional work including;
- The overhaul of the MAN B&W 6L 27/38 main engine,
- Overhaul of 3 x Volvo Penta 300Kva auxiliary generators and the 800Kva shaft generator,
- Hull treatment – including a change of topsides colour to the company’s ‘red’ brand,
- Assisting with Classification Societies close up survey requirements in ballast tanks and cargo tanks,
- Assisting specialist contractors with testing and maintenance requirements for the vessels Life Saving Appliance equipment.
Again, very good feedback was received from the both the Ship and the Owners Rep, commenting in particular on the professionalism of those they had worked with at Babcock.
MV THOR SIMBA
Our biggest steelwork project for the year was the 5,900 DWT, 100 metre LOA General Cargo vessel Thor Simba in June / July 2006.
The project required approximately 30 tonnes of steel renewals through double bottom and wing tanks, as well as further steel repairs to ships hatch covers and cargo cranes. Other work included hull painting, overhaul of crane sheaves and deck equipment and repairs to machinery space pipe works and ships boilers. Survey work included overhaul of steering gear, sea valves and underwater fittings, shaft generator alignment and servicing of main engine turbocharger coolers. The Thor Simba was in dry-dock for 14 days with an additional 4 weeks on Babcock’s repair berth. On completion the vessel was re-named Southern Pearl for charter between New Zealand and the Pacific Islands.
Voyage repair assistance was also provided to the Thor Simba earlier in the year in the form of overhaul of spare cylinder heads for the vessels MaK 6M551AK main engine as well as overhaul and refractory repairs to ship’s boiler.
ARAHURA
Toll Shipping’s 13,621 GRT New Zealand based Ro/pax vessel Arahura which operates on New Zealand’s Cook Strait, made a welcome return to Babcock’s Auckland dry-dock in July/August for a 21/2 year survey docking.
The work package included high pressure water blasting and painting of hull, superstructure and focsle deck. Survey work included the removal of underwater valves, opening up shaft line bearings for survey and repair and installation of new watertight subdivision bulkheads in crew accommodation spaces to meet SOLAS requirements. Repairs were also carried out to machinery space and drencher pipe work, electrical motors, refurbishment of accommodation lounges, general steel and mechanical repairs and assistance with lifeboat testing. The docking duration was 12 days.
MONTE STELLO
The largest mechanical project for the period was the 11,630 GRT Ro/pax Ferry Monte Stello which dry-docked with Babcock in March for a Class Renewal Survey and accommodation works.
This was the first New Zealand docking for the vessel following a delivery voyage from Spain for the new owners Strait Shipping. The approx. 20,000 man-hour work package included overhaul of both Pielstick 12 P02.5 main engines and general machinery space survey and repairs. New installations included of a new sewage treatment system, new life raft davit cranes and with ship side guard rails, extensive under deck fire protection insulation was carried out, along with installation of new bilge keels, renewal of forepeak tank top plating. There was also conversion of approx 20 boat deck overnight cabins to a day lounge area including new seating and audio/ visual services. Approximately 6,000 sqm of underwater hull and topsides were water blasted clean, then painted in Strait Shipping’s blue and white livery. The Monte Stello is now in operation on Strait Shipping’s Bluebridge ferry service across New Zealand’s Cook Strait.
ATHENA
The 80 metre superyacht Athena spent 10 weeks at the yard prior to Xmas 2006.
2 weeks of this time was spent in dry-dock so that the existing anti-foul could be removed and replaced with new Trilux 33 anti-foul coatings. Being a superyacht and for reduced risk of damage to coatings, instead of the more usual ultra high pressure water blasting paint removal process, the anti-foul was removed using a soda washing process which was a first for the yard on a large vessel. To protect topside coatings from possible overspray the underwater hull area was encapsulated, with the encapsulation process worked around the clock to ensure that the work package could be completed in the 14 day dock window available. The Athena is, we understand, the largest 3 masted schooner in the world and certainly caused a lot of public interest whilst at the yard.
CLIPPER ODYSSEY
The 5,128 GRT boutique cruise ship Clipper Odyssey was dry-docked by Babcock in December 2006.
This years docking required about 18,000 man hours over a 4 week period with the critical path being the removal, overhaul and replacement of the vessel’s 2 fin stabilizers and removal of tail shaft and propeller to the workshop for overhaul and to facilitate repairs to stern tube seal. Other engineering works included; overhaul of main engine cylinder head units, servicing of boiler & economiser, water ballast pipe work repairs, installation of replacement reverse osmosis plant, and general survey work and external hull painting. Hotel work included fitting of new carpets through guest accommodation areas and tiling of cabin bathrooms and refurbishment of passenger gangway and access areas. On completion of docking the Clipper Odyssey will carry out a number of 7 and 14 day cruises in New Zealand waters prior to continue her itinerary through Australia then on to Asia.
HMNZS Te Kaha (KHR17) Selected Restricted Availability
Launched on 22 July 1995 and commissioned two years later, Te Kaha is the first of the RNZN ANZAC class frigates, similar in design to a Type 23 frigate. Te Kaha has a displacement of 3600 tonnes and an overall length of 118 metres. Capable of 27 knots, propulsion is from a combined diesel (two MTU 12V 1163 Diesels) or gas turbine (one GE LM 2500 gas turbine) driving twin shafts and controllable pitch propellers.
Babcock undertook a 9 week SRA (Selected Restricted Availability) of Te Kaha between April and June, 2007. The majority of the package was scheduled to be conducted whilst the vessel was dry-docked at the Devonport Naval Base.
Key activities
- The removal (via Babcock developed procedure) involving side shell plate removal and major equipment removals) of 2 x 1000kW forward generator prime movers and their subsequent renewal.
- 22 Engineering Change Projects including;
a. Phase1 of mini typhoon point defence weapons system;
b. Gyro stabilised helicopter landing guidance systems;
c. Seatel C band communications system;
d. Satellite television receiving equipment;
e. Complete secure wide area network;
f. 2 x reverse osmosis water generation plants;
g. Fwd section flood detection system;
h. Major galley equipment upgrade; and
i. Cross connection fuel pipe work. - 7500 hours of coating repairs.
- Stabiliser removal, repair and re-installation.
- OPDEF rectification including propeller shaft air masking tubes repairs.
Outcome
Following a successful Terminal Date inspection, Harbour Acceptance Trials (HATS) and Sea Acceptance Trials (SATS) were undertaken by the RNZN. All systems commissioned satisfactorily and there were no major equipment issues identified.
Customer relationships were maintained at very positive levels throughout the project, with excellent feedback being received by Babcock from both the Fleet Engineering Centre and Ships Staff.
Ports of Auckland Crane Maintenance
Project Summary:
Overhaul of 4 tonnes SWL overhead travelling maintenance cranes for Ports of Auckland.
Overhaul included dismantling crane to its main components ie jib, platform, drive trains.
The cranes were then Inspected and repaired as required. This included the cable drum and slewing motors and gearboxes, overhaul of cable rollers, as well as structural survey and repairs and replacement of the electrical control box.