“Antartic Sea” (Factory fishing vessel of krill flour that was converted in our shipyard into a factory fishing vessel of krill flour and krill oil (Norwegian)).
The conversion, that reached 180 ton total weight of new steel, included the following outstanding ítems:
a) Construction of:
• four new tanks for the new production process, located in the afterward zone of the existing hold;
• new dewatering room for the new production process, located on the new main deck beside the existing accommodation;
• new trawl workshop room on the existing main deck;
• new main deck for substituting the previous one between the existing accommodation and the new trawl workshop;
• new control room for the new production process;
• new platform at starboard side forward of existing hold.
b) Fabrication and assembling of:
• 300 meters of new steam pipe inside process rooms;
• 260 meters of new hydraulic pipe for operation of main deck new equipment: cranes and winches.
c) Assembling of:
• new hydraulic equipment on main deck: three cranes and six winches;
• two pumps and two new tanks inside the cofferdam in way of the existing accommodation;
• new equipment inside the dewatering room for the new production process: centrifugal separator, screw distributor, ducts, pipes and three new air compressors
TSHD Reynaert (Trailing suction hopper dredge (Belgian)).
Dredge general maintenance including the following outstanding ítems:
a) hopper steel renewal;
b) tailshaft generator maintenance;
c) several electric motors maintenance, including the bow thruster electric motor;
d) bow thruster propeller blades repair;
e) sheave bronze bushes renewal of the cranes and of the several manoeuvering arrengements of the dredging system;
f) provision crane general overhauling;
g) general disassembling and maintenance of the three generator diesel engines, including: cylinder heads with their valves and valve seats, pistons, connecting rods, liners, oil filters;
h) disassembling and maintenance of the three gear boxes clutches;
i) dredging pump rotor machining;
j) disassembling of hopper water overflow device, steel renewal and central hydraulic cylinder replacement;
k) dredging pipe miscelaneous jobs:
• individual pipes disassembling;
• fabrication, welding and following machining of their pad eyes;
• renewal of washing pipe shaped parts;
• disassembling of its universal joint elbows to fill up with electric welding and to machine in situ their faces and holes arms;
• interior surface filling up of universal joint elbow with hard electrode and with a specific geometrical filling up design, in order to minimize the abrasive wear;
• machining of all the holes of the universal joint eight sided structure.
l) engine and pump room pipes renewal;
m) two rudder blades disassembling, bush housings in situ machining and new bushes machining and assembling.
Hang Jun 3001 (Trailing suction hopper dredge (Chinese))
Renewal of the pipe rods (8" nominal diameter, schedule 80, approximately 14 meters length) of the 16 hopper valves, assembled between the hydraulic actuator and the disc.
The renewal process for each rod included: to disassemble the actuator-rod set and transport it to the workshop; to substitute, at the workshop, the existing rod by the new one, employing the required cutting, positioning and welding; to perform, at the dredge, steel repairs in the disc actuator guides; to transport the actuator-new rod set to the dredge and assemble it on its corresponding position; to weld the new rod to its disc; final operation and watertightness tests.
HANG JUN 4011 (Chinese trailing suction hopper dredge) - Dismounting, fabrication/repair and mounting of dredging piping system parts (800 mm. diameter) in pump room and on main deck, including: a) cylindric pipes; b) elbows; c) conic pipes; d)tees; e) external doubler plates for straight pipes.
ISKATEL 2 (Italian support vessel) - Four impellers (four diesel powered pumps) installation for the new vessel dynamic positioning system: a) hull cutting and welding of eight hull flanges for pump pipes; b) manoeuvering and positioning of base-pump sets; c) pipes installation; d) mounting and welding of the base structures to the hull; e) mounting of diesel engines on such bases and alignment with the pumps; f) installation of cooling and exhaust pipes.
Important repair that included jobs of very different type. The following jobs are those which must be enphasized: a) “A” frame fabrication and installation; b) two service frames fabrication and installation; c) hull and main deck steel renewal; d) dredging pumps overhaul; e) dredging pipes repair; f) hopper bottom doors maintenance; g) tailshafts (2) dismounting; CPP propellers (2) full disassembling; spare parts calibration, machining and fabrication; CPP propellers assembling and testing; tailshafts mounting.
Overhauling of its two azimuthal stern thrusters, including for each unit: upper transmission box dismounting and removal from the ship; fix pitch propeller dismounting; thruster (nozzle and lower transmission box) removal; transportation of all these components to our workshops, where they were completely disassembled, inspected and calibrated; roller bearings renewal; new propeller blue fit test; final workshop assembling; transportation of all the components to the ship, manoeuvering and definitive mounting.
Conversion of all the main deck fishing equipment, including: to remove all existing equipment; to build the new generator room and the electric panel room for the new equipment; to extend life-boat deck; to modify accommodation (cabins, toilettes, staircases) and bridge; to close main deck passages in way of accommodation both sides and install rails for the fishing manoeuvring on such deck; to extend stern platform and fabricate and install on it, new fishing door structures and supports; to fabricate and install on the main and life boat decks and on the stern platform, the bases of 22 new winches; to install such winches; to install the new generator, including the fabrication and mounting of all the pipes and tanks associated with. The weight of the new naval steel constructions was 70 tons.
Overhauling of the main engine reduction box and clutch, including: complete disassembling; inspection and calibration of their parts; in situ machining and bushing of rolling bearing housings; rolling bearings, shafts, gears and clutch discs renewal; final assembling.
Renewal of the complete set of seismic cable winches and reels (4 units of 5 meters diameter and 17,5 tons weight each), including: a) Cropping off and transient removal of upper and helicopter deck areas, in order to allow the removal of the existing four seismic cable winches and reels; b) Cropping off and removal of the existing four seismic cable winches and reels and their foundations; c) Fabrication and installation of foundations and reinforcement structures for the new four seismic cable winches and reels; d) Reception of the parts of the new four seismic cable winches and reels; assembling of such winches and reels on the pier; manoeuvring, installation, alignment and starting up of them on the ship; e) Final installation of transitorily removed areas of upper and helicopter decks.
Partial renewal of propulsion and steering systems (propeller, nozzle and rudder), including: a) Removal of propeller shaft and propeller; reception of new propeller, machining of its central conic bore, conic milling of its keyway and blue test fitting of its conic bore on the propeller shaft cone; installation of propeller shaft and hydraulic assembling of propeller; b) Reception of the nozzle; fabrication and installation of the steel structure required for its entailment with the hull and the stern post; installation, alignment and welding of the nozzle, with continuous control of propulsion and rudder system lines; c) Removal of rudder and rudder stock; fabrication and installation of "tail fish" and new steel plates on upper and lower rudder areas; final assembling of rudder stock and rudder.
ALIANÇA ANDES. Complete renewal of wave breaking bulkhead (24 x 6 meters gross dimensions and 24 tons weight), including: a) Complete removal of damaged wave breaking bulkhead, including supporting structures, hold accesses, ventilation ducts and electric panels; b) Complete removal of mast and lightning fixtures; c) Fabrication and installation of new wave breaking bulkhead; d) Fabrication of a new mast section, assembling of such section with the existing section and installation of complete mast; e) Reparation and/or fabrication and assembling of the others removed elements.
The damage to be repaired was the separation -during navigation- of the rudder upper casting -where the rudder stock is coupled- from the rest of the rudder. In these conditions, the upper casting remained coupled to the rudder stock, and the rudder got free, without any possibility of moving, only related with the ship by the pintle located in its horn housing, and laying on it.
The repair -performed with the ship afloat- was, mainly, as follows: disassemble the rudder (42 tons), the upper casting and the rudder stock (13 tons); renew the rudder naval steel plates (Grade E) affected by the damage; build up by electric welding the inside cone of upper casting and locate it at its original position in the rudder; perform the welding keeping a sharp alignment control, doing X rays tests and 100% ultrasonic test; machine such inside cone and its two keyways; perform its fitting with the rudder stock lower cone. While this was done at the workshop, in the ship the jobs were: remove rudder stock neck and pintle bronze bushes; machine "in situ" their housings; install new bushes fabricated at the workshop. Finally, the rudder stock and the rudder were assembled in the ship, with the owner and Classification Society total approval and satisfaction.
Since 2002 the company has successfully participated in the demanding repair market of container ships belonging to German owners. Up to now, more than 40 ships of this type have been repaired both in our shipyard and in the Montevideo harbour piers.
The company has lately broken into two new markets: research ships, of which we have repaired the "GSI ADMIRAL" and the "LAURENTIAN", both dedicated to the detection of submarine petroleum deposits; and the ferrys that attend the Buenos Aires-Colonia and Buenos Aires-Montevideo lines, of which we have repaired the "ATLANTIC III" and the "ALBAYCIN".
Complete manufacturing of fishing vessel "GRAMPIAN FURY" rudder-nozzle, including: shaping, assembling and steel welding; machining of coupling flange and pintle conical housing; drilling of coupling flange calibrated holes; pintle fitting inside its conical housing.
Main engine complete overhauling of "KENT TRADER", including: a) disassembling, cleaning, inspection, calibration and assembling of cylinder heads, pistons, connecting rods, connecting rods bearings, main bearings and turbochargers; b) original crankshaft disassembling and assembling of a new crankshaft supplied by the Owner.
Removing from the ship, placing on ground over suitable supports, grit blasting and painting of special rubber seal housings, renewing such special seals and performing miscellaneous steel renewal jobs, to the 19 hatch covers (12,5 m x 10,3 m, 28 ton each) belonging to the "MERCOSUL PESCADA" (German container ship).
Renewal of 80 tons. of naval steel plate belonging to hold bulkheads and hatch covers, of the open hatch bulk carrier "PIPIT ARROW" (ex "TOKI"), simultaneously with the surface treatment of 14,000 m2 of hold surfaces gritblasting to SA 2 ½ and application of two coats-.
Renewal of 100 tons of naval steel plate belonging to the double bottom tank ceiling and its associated internal structure, of fuel tanker "ALIA".
Disassembly and assembly of starboard side rudder blade and tailshaft of cruiser "EXPLORER II" , for white metal rebabbiting of both stern tube bearings: a) partially, the fore located bearing, aprox. 460 mm inside diameter and 500 mm length; b) totally, the after located bearing, aprox. 460 mm inside diameter and 1,200 mm lenght.
Complete repair of stern area of bulk carrier "ONEIDA" affected by its main engine exhaust gases boiler explosion, including: A) complete fabrication and assembly of: main engine, auxiliary engine, main engine exhaust gases boiler and incinerator exhaust pipes; water pipes; thermal insulation; ventilation ducts and intake pieces; provision cranes; B) assembly of new main engine exhaust gases boiler; C) renewal of steel plate and associated structure in accommodation and stern decks; D) complete rearrangement of accommodation, corridors, dining room, and others areas: bulkheads, panels, floors, ceilings, doors, lighting fixtures; E) main and auxiliary engines maintenance.
Renewal of 200 tons. of naval steel plate and associated internal structure belonging to cargo tanks of chemical tanker "ANTARES I" , including: cropping off of damaged steel plates, construction of templates for shaped steel naval plate fabrication, making of specific repair drawings, fabrication of shaped steel naval plate with single and double curvature, assembling of plane and shaped steel naval plate, final welding, X rays testing, final approval.
Renewal of 80 tons. of special naval steel internal structure belonging to the wing ballast tanks, of the bulk carrier "NEWCASTLE CITY"
Complete repair of rudder system, including: alignment checking and resultant "in situ" machining of hull; rudder blade and rudder stock liners renewal; cones rebuilding, machining and fitting in rudder stocks, pintles and rudder blades; steering gear overhauling; final assembling; of the following M/V vessels: "SEA EXPRESS", "PRESIDENTE ARTURO ILLA" (YPF tanker), "GIANNIS NK" , "GOLD ROVER" (British Navy), "TOBA PEGASO", "NILZA" (PETROBRAS tanker), "CAMINO", "ESTRELLA ATLANTICA" (SHELL tanker), "CHARMYL", "SAGA TUCANO" (Hongkonish open hatch bulk carrier built in 1997), "MAERSK ROSARIO" (German container ship).
Dry docking of "PROLIV NEDEZDHY" -for a no permanent repair that allows her to recover her navigability- that had experienced an important damage of bottom steel plate hull, in way of double bottom tanks that were full of oil. Several actions were taken in order to prevent an eventual oil spillage during docking manoeuvre.
Afloat renewal of tailshaft outside seal, of "ROSS SEA", including disassembly and assembly of propeller, 20 tons weight.
Partial tank coating -grit blasting SA 2 ½ and one or three coats (depending on the paint schedule applied)- performed on approximately 7,000 square meters for each ship, in the following light fuel tankers owned by PETROBRAS: "NILZA" , "NORMA", "DIVA", "NARA", "LAMBARI", and "LIVRAMENTO".
Repair of rudder blade (aprox. 7,500 mm. x 3,500 mm. 20 tons. weight), including: dismantling; alignment control; preparation to avoid distortion during cropping off and welding; cropping off of cracked areas on pintle cone end cast steel housing and nearby plating; installing and welding of required new naval steel plating, applying suitable heat treatment and checking alignment distortion during welding; X rays tests and ultrasonic tests on welds; final straightening process in order to improve remaining misalignment, by heat and hydraulic force suitable application; fitting improvement of pintle tapered end in its housing, with required number of blue tests included; final assembling on ship, of M/V "MSC ARGENTINA" (German container ship), M/V "LAMBARI" (PETROBRAS tanker), M/V "CASTILLO DE GUADALUPE" (Spanish general cargo, previously owned by DOCENAVE).
NORDAMERIKA (Danish chemical tanker built in the year 2000)
Hydraulic disassembly of: rudder, steering gear and rudder stock, and transport them to the Workshop
Draw rudder line, through their upper and lower cones. Machine “in situ” its lower casting, fabricate cylindrical-conical insert and installe it in such casting. Make pintle fitting in its lower casting conical housing and rudder stock fitting in its upper casting conical housing, by the required number of blue tests.
Place the new rudder stock, supplied by the owner, on the lathe; machine its area in way of its bearing located in the rudder horn. Fit its lower cone in the rudder and its upper cone in the steering gear, by the required number of blue tests.
Remove the seriously damaged existing rudder horn; clean and chamfer carefully all hull plates edges related with rudder horn; install new rudder horn, align it and weld it to the corresponding hull plates, by X rays controlled welding; draw final rudder system line and machine "in situ" both horn bush housings: the upper for the rudder stock and the lower for the pintle; fabricate and install such bushes in their respective housings.
Renew steel plates of the steering gear room floor and its associated structure, including the base of the steering gear, in way of such equipment.
Transport the rudder to the ship and manoeuvre it to its position. Transport the rudder stock to the ship, monoeuvre it to its position and assemble it hydraulically to the rudder. Transport the steering gear to the ship, monoeuvre it to its position and assemble it hydraulically to the rudder stock.
Verify the actual clearance between each steering gear support and its base; consequently, fabricate one steel chock for each support, fit them one by one "in situ" to each support and drill them, supplying the corresponding fixing bolts.
Hydraulic disassembly the propeller: four blades, diameter 6,150 mts, weight 15 tons, and transport it to the Worshop.
Straighten three of its four blades, which presented initial axial deformations up to 720 mm, by fabrication of specific tools and thermo-mechanic special treatments. Perform final pitch control.
Disassemble propeller shaft from intermediate shaft; perform opening on the hull in way of engine room, in order to allow removal of such shaft to the Workshop. Once in the Workshop, present the propeller shaft on the lathe, to check its alignment.
Transport propeller and propeller shaft to the Dock. Perform on the dock platform, in vertical postion, the fitting of the propeller shaft stern cone in the propeller cone, by the required number of blue tests.
Introduce the propeller shaft in the engine room, manoeuvre it to its position and assemble it with the intermediate shaft; blank and weld the hull opening.
Manoeuvre the propeller to its position and assemble it hydraulically to the propeller shaft.
Works in main and auxiliary diesel engines (Sulzer, MAN B&W, Pielstick, Mitsubishi, Cummins), including: partial or complete units overhauling, crankshaft substitution, parts repair, complete assembly.
Renewal of 70 tons. of naval steel plate belonging to fore peak, chain lockers and hold Nº 1, of the bulk carrier "VALY", including: cropping off of damaged steel plates, construction of templates for shaped steel naval plate fabrication, making of specific repair drawings, fabrication of shaped steel naval plate with single and double curvature, assembling of plane and shaped steel naval plate, final welding, X rays testing, final approval.
Complete repair of rudder system, with same description as "SAGA TUCANO", but including in this case: straightening and stress relief of bent rudder stock (360 mm. diameter with eccentric flange, 6,000 mm. length, 8 tons. weight), of M/V "GEMARELLA".
Construction of a "micro" floating dock to perform afloat inspections of rudder systems of oil tankers "PALM BEACH" and "BAYWAY", owned by ESSO Argentina.
Inspection and repair of lower pintle and skeg bush, of oil tanker "PALM BEACH", using such "micro" floating dock.
Complete tank coating of cargo tanks -grit blasting SA 2 ½ and one or three coats (depending on the paint schedule applied)- performed on 21,500 square meters for each ship, in the following light fuel tankers owned by PETROBRAS: MARTA, NORMA y DILYA.
Renewal of 690 tons. of naval steel plate and associated internal structure, belonging to flat and vertical bottom of the bulk carrier "ADAMASTOS", including: a) cropping off of damaged steel plates, construction of templates for shaped steel naval plate fabrication, making of specific repair drawings, fabrication of shaped steel naval plate with single and double curvature, assembling of plane and shaped steel naval plate, final welding, X rays testing, final approval; b) renewal of all the ballast pipes in way of the damaged double bottom tanks; c) alignment control of propulsion and steering systems.
Complete repair of rudder system of M/V "ZONDA I", performed afloat, using a watertight box.
Afloat joining of two parts of existing floating dock of Tsakos Industrias Navales S.A., including all works related with welding, piping, valves, electricity, launching and cranes.
Afloat repair of floating crane "TENIENTE DEL CASTILLO", owned by Ecogesa (Hotchief), including complete disassembling and assembling of jib, tower and side supports, with difficult manoeuvring performed at 40 mts. height.