Introduction
In Shanghai, our team carried out comprehensive propulsion system maintenance on an offshore cable-laying vessel to ensure continued reliability and optimal performance. We serviced the vessel’s thrusters, which included 1x Brunvoll FU80, 2x AR 63 tunnel thrusters, and 2x AR 63 retractable azimuth thrusters. Our work involved seal replacements, thorough inspections, and servicing to address wear and tear, prevent potential failures, and minimise unplanned downtime. These efforts ensured the vessel remained operationally ready for its critical offshore operations.
Plan
The team conducted a risk assessment and method statement review, collaborating with the client’s superintendents, chief engineer, and the shipyard, while also reviewing the work schedule and the required yard assistance. To ensure the success of the job, Bartech Propulsion supplied bespoke specialist tooling tailored for the unique requirements of the thruster maintenance. This ensured efficiency and precision throughout the process. Thruster components were disassembled and transported to the workshop for detailed inspection, seal replacement, and reassembly, followed by rigorous testing.
Execution
The project began with the dismantling of key thruster components, including the propeller hubs and OD boxes. After disassembly, the parts were carefully transported to the workshop for detailed evaluation. Bespoke specialist tooling designed specifically for thruster servicing was employed during the disassembly and inspection phases. This tooling allowed for safe and accurate handling of critical components, ensuring alignment with OEM standards, and contributed to the overall efficiency and precision of the process.
Once at the workshop, we conducted thorough inspections, which included crack testing the propeller blades and closely examining the bearings and gear conditions. This meticulous process was critical for identifying wear and any potential issues that might affect future performance.
Following the inspection phase, all seals and liners were replaced before the units were reassembled. To confirm the thrusters’ functionality and ensure optimal performance, we carried out pitch tests, which verified the operational integrity of the reassembled units.
The project did present some challenges. One notable obstacle was the need for hydraulic tooling, which we successfully resolved in collaboration with the client by sourcing the required equipment locally. Additionally, close coordination with the shipyard was essential as we managed deck modifications to facilitate the work.
Results
The project concluded with all thrusters successfully restored to optimal condition, with no leaks detected during final inspections. Both pitch and static tests confirmed precise functionality, significantly reducing the risk of operational failures and ensuring reliability. Moreover, the service was completed within the planned schedule, allowing the vessel to be fully prepared and ready for its next operational cycle without delays.
Key Takeaways
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