WORLDWIDE RAPID RESPONSE

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1 UNDERWATER MAINTENANCE Security Inspections Class approved inwater surveys Underwater hull cleaning Underwater propeller polishing Underwater propeller repair & replacement Class approved permanent hull insert repairs Underwater plate thickness determination Underwater coatings & adhesives Underwater welding Stabiliser fin replacement ICCP system replacement Propulsion system replacement Stern seal replacement Underwater sensors & sonar installation, repair & replacement Underwater acoustic cladding, installation and repair SBM subsea maintenance Hydrographical surveys WORLDWIDE RAPID RESPONSE for inwater maintenance & through life waterborne support DESIGN & CONSULTANCY Marine engineering consultancy Project management Engineering design optimisation Reduction of dock dependency Hull survey methodology Acoustic cladding systems management Underwater coating, bonding & fastening solutions 3D modelling Cofferdam design & manufacture EQUIPMENT SUPPLIES Neutrally buoyant hull aperture blanks Afloat engineering support equipment Underwater hull cleaning equipment Underwater applicable coatings

2 UNDERWATER MAINTENANCE HULL CLEANING THE MINI PAMPER UMC s fast, and versatile Mini Pamper hull cleaning system. Mini Pamper An innovative approach to fouling control with a new generation of afloat hull cleaning equipment. COST SAVINGS Fuel saving is the major reason for making underwater hull cleaning an integral part of planned maintenance. A build up of marine fouling can lead to increased drag, resulting in a detrimental impact on a vessel s hydrodynamic performance and hence the relationship between speed, power performance and fuel consumption. Fouling, particularly in the case of a prolific buildup of hard or shell fouling like barnacles or tubeworm, can cause turbulence, cavitation and noise, frequently affecting the performance of sonars, speed logs and other hull mounted sensors. THE MINI PAMPER A versatile, compact hull-cleaning machine, capable of removing mild or tenacious hull fouling from a variety of coatings; including the new low surface energy coatings being introduced into service. Mini-Pamper was initially designed for cleaning acoustically clad submarines where the absence of any antifouling paint meant that Mini-Pamper had to deal with extreme marine growth without damaging the fragile surface. Mini-Pamper allows the operator to bring a choice of cleaning heads gently into contact with the hull until they are just cleaning and no more. Having selected the correct cleaning pressure, the machine will automatically maintain this level. Detailed view of a hull showing the area before and after cleaning.

3 UNDERWATER MAINTENANCE PROPELLER SUPER POLISHING THE POLISHING PROCESS Underwater propeller polishing is firmly established as an important aid to efficiency and fuel saving. WHY POLISH PROPELLERS? The sole purpose of polishing a propeller underwater is to reduce the surface roughness. The bottom line for the customer depends on the cost of the service deducted from the financial savings resulting from the polish. Provided the job is done properly, the cost of the underwater polish will only be a small proportion of the fuel savings, and therefore the most important factor to be considered by the customer is the quality of the polishing. HOW DO WE POLISH PROPELLERS UNDERWATER? A super smooth surface is inhospitable to marine organisms as well as being beneficial to the efficiency of the propeller. UMC have constantly improved the standard of their surface finish. A recent enhancement to meet stringent military requirements involved a major redesign to provide a higher power rating combined with exceptionally fine abrasives. Our equipment provides a suction force of 100kg to the propeller surface but can be maneuvered over the blade face easily by the diver. We can use abrasive sizes down to 360-grade grit to produce a surface finish of 0.5µ Ra. Images top to bottom: 1. Typical fouling on the surface of a rough propeller. 2. Halfway through the underwater polishing process. 3. Diver administering first (coarse) grade abrasive polish. 4. Blade after super polishing.

4 CLASS APPROVED INWATER SURVEYS AND INSPECTIONS Sea Valve Inspections UMC s neutrally buoyant hull aperture blanks (see separate data sheet) allow afloat inspection of sea valves if required as part of the survey. UMC has approval from all the major classification societies to carry out in-water surveys for extension and in lieu of dry docking. THE SURVEY To provide high-quality images UMC ensure that their equipment is optimised to match the prevailing underwater conditions by using CCTV and high resolution cameras that are sensitive to low light levels. Our full technical reports include underwater photographs and CCTV video recording. We also have the ability to include CAD generated drawings where necessary. WORLDWIDE SERVICES Sales Surveys Sea Valve Inspections Extension to dry docking In-Water surveys in lieu of dry docking Underwater paint / thickness inspections Plate thickness readings ROV SERVICES Underwater Security Inspections Impact damage inspection Specialist propeller crack detection Hull potential surveys Hydrographic surveys Jetty Inspections Underwater side-scan sonar technology and GPS tracking combined with on-board forward and aft CCTV video cameras, depth-rated to 300m give UMC the capability to carry out salvage and sea bed inspections; visual hull analysis; portable and fly away worldwide service. Close up inspection of impact damage. Specialist propeller crack detection equipment.

5 UNDERWATER MAINTENANCE PERMANENT HULL INSERT PLATE REPAIRS AND COFFERDAMS REMAINING RUNS BUILT UP USING LOW HYDROGEN WELD ELECTRODES FIRST PASS TIG WELDED New plate positioned from inside as seen during initial root weld process. Inset shows how the layers of runs are applied to produce a permanent, high quality weld. Insert plate close-up Welding cross section AFLOAT REPAIRS UMC have developed a procedure that allows defective areas of shell plating beneath the waterline to be cut out and replacement insert plates to be welded into position whilst the vessel is afloat. COFFERDAMS UMC designs, manufactures and installs unique cofferdam systems that allow afloat repairs to be carried out on vessels and offshore installations around the globe. By fitting an external cofferdam a dry environment is created to allow internal access by coded welders. This technique has received Class Approval as a PERMANENT repair, without imposing a Condition of Class on the vessel. Underwater external weld seams before and after painting. No underwater welding is required for this repair procedure.

6 UNDERWATER REPAIR STERN SEAL REPLACEMENT AND REPAIR The inflatable habitat is fitted around the stern seal area creating a water tight fit. UMC divers have been trained and certified in the bonding of stern seals. THE SERVICE UMC International has extended its capabilities to provide underwater stern seal replacement and repair services. Being strategically situated at key global sites will greatly benefit the commercial shipping industry by further reducing the need to dry dock for repairs or maintenance anywhere in the world. THE TECHNOLOGY The stern seal technology is a man-entry inflatable habitat that fits around the stern shaft to ensure a dry environment is created for the seal replacement or repair. Constant monitoring of the habitat insures a safe working environment is maintained at all times. The system is both lightweight and robust and can fit a variety of vessel sizes and stern configurations from conventional shafts to pod propulsion systems. The habitat can be transported worldwide and assembled within a few hours while your vessel is at dockside. Divers enter the habitat to begin the seal repair. Underwater stern seal replacement and repair services include: Lip seals, dry repair and replacement of complete systems including seal bonding Face seal wet repairs and replacement Stern tube sealing to facilitate inboard repacking of water lubricated stern seals UMC carry out pre-deployment checks of stern-seal replacement system in preparation for flyaway operations.

7 UNDERWATER MAINTENANCE SPECIALIST WELDING UMC s welders are highly experienced in all aspects of specialist underwater welding, including high tensile and more recently high carbon equivalent steels. Highly Qualified Staff UMC have an extensive track record of underwater welding contracts. Applications for underwater welding are vast and UMC employ full time divers with underwater welder qualification to ANSI/AWS D3.6-93Class B welds, certified by Lloyds Register of Shipping. Typical Applications Sacrificial anode replacement Impressed current anode replacement Rope guard repairs Rudder repairs External doubler plates Sealing up disused inlet and outlet First-degree damage control for marine casualties New Purpose-Built Test Facility With a recently installed state-of-the-art Test-tank facility at headquarters in the UK, UMC personnel are now able to have continuity of training, prequalification of new procedures and consumable evaluation in a controlled environment. Anode replacement Weld repair Weld seam Diver welding in UMC tank

8 DESIGN & CONSULTANCY OFFSHORE SERVICES AND PRODUCTS 3D image showing spud can cofferdam UMC designed, manufactured and installed a unique cofferdam to support afloat repairs of all three spudcans of a jackup oil rig. Knowledge & Experience Following over 30 years success in providing afloat engineering solutions for commercial and naval shipping, UMC International has developed a number of products and services in support of offshore platforms and FPSOs. Our specialist team of engineers and naval architects develop innovative solutions to problems requiring underwater intervention to avoid dry-docking of platforms. The team designs all the necessary equipment and documentation, including procedures and risk assessments, whilst maintaining a strong background in project management thus ensuring larger projects can be fully supported from concept design thro manufacture and on to site support. UMC s involvement in the offshore industry encompasses equipment sales, consultancy services and personnel. OUR SERVICES A global diving support network and provision of personnel. Hull cleaning using customised cleaning equipment, allowing class inspection. Hull aperture blanks for sealing hull openings and sea chests. Class approved designs ranging from 0.5m 2 to 5m x 3m and in excess of 7000 produced. ROV installed and operated sea chest blanks for FPSO Insert plate repair using Class approved procedures and dry single sided welding. Underwater painting using specialist procedures and equipment to apply a range of anticorrosive and antifouling coatings. Thruster, stabiliser and rudder replacement using well-proven procedures and experience gained on commercial and military shipping. Inspection and NDT including crack detection, paint and plate thickness measurement. Cofferdam solutions for spud can repairs, repairs to leg linings, hull plating repairs and repairs to rudder plating. ROV installed and operated sea chest blank Underwater inspection Azimuth Thruster replacement T: +44(0) F: +44(0) offshore@umc-int.com

9 UNDERWATER MAINTENANCE PROPELLER REPAIRS AFLOAT Specialist underwater propeller repairs and modifications. Divers cold bend a damaged propeller to restore original profile. The Survey UMC International offers ship operators technically sophisticated solutions to propeller damage and associated performance problems in co-operation with Subsea Propeller Incorporated (SPI), the underwater propeller repair specialists for Wartsila. Through this association, UMC is able to perform underwater shopquality repairs, which, in many cases, are considered as permanent by the Classification Societies. UMC and SPI now accomplish repairs underwater that, until recently, could be done only in propeller shops. In order to provide this service, UMC personnel have undergone extensive classroom and on-the-job training in propeller repair. This training has included operating SPI s specialized equipment and techniques. Experienced propeller specialists perform all repairs, and when necessary, a hydrodynamicist provides in water assistance and supervision to ensure shop quality is attained. UMC and SPI offer this service around the globe. Repairs are usually accomplished at a vessel s scheduled stop without causing delay or interruption. Cropped and dressed blade tip Super polishing to less than 1 micron Our Services Include Straightening of blade bends Accurate identification and documentation of blade damage, including detection of micro-fractures Establishment of hydrodynamic contour Restoration of propeller mass and hydrodynamic balance Contour modification to correct cavitation Edge modification, including anti-sing correction Correction of propeller-induced engine overload ACFM (Alternating Current Field Measurement) detection for cracks Removal of damaged blade sections with minimal loss of propulsive efficiency Super polishing to less than 1 micron Before and after propeller repair

10 UNDERWATER MAINTENANCE FIXED FIN STABILISERS T23 stabiliser following removal UMC have developed the procedures and equipment to carry out afloat replacement of fixed fin stabilisers and bearings fitted to Royal Navy surface ships. STABILISER MAINTENANCE During removal and replacement the stabiliser fin is supported using a combination of internal and external rigging. An internal cofferdam arrangement is used inboard to maintain the watertight integrity of the hull as the stabiliser fin is removed. The stabiliser fin is then lowered from the ship by progressively easing the internal and external rigging until it can be connected to a dockside crane, disconnected from the rigging & recovered to the dockside. Once the stabiliser is removed, the hull opening is blanked off using an external cofferdam so that the water can be drained, allowing disassembly of the internal cofferdam and stabiliser components. This provides access to the main bearing so that it can be inspected and or replaced as necessary. The stabiliser fin is then installed following the reverse of the removal procedure. Where inboard (top) bearings form part of the stabiliser assembly, UMC s procedures and equipment allow replacement without having to remove the stabiliser fin from the ship. Internal cofferdam arrangement CUSTOMISED FLYAWAY CONTAINER Typically, all of the equipment needed for stabiliser replacement is supplied & stored in standard 10ft & 20ft ISO containers for transport worldwide. To date UMC have supplied equipment to the RN for stabiliser replacement on CVS, T42, T23 and T22. Customised fly-away container

11 UNDERWATER MAINTENANCE VOITH SCHNEIDER PROPELLERS UMC have developed the capability for the afloat replacement, underwater inspection and propeller polishing of Voith Schneider Propellers (VSP) fitted to Naval & Commercial vessels. VSP REPLACEMENT Replacement of a VSP unit is carried out afloat using a cofferdam (positioned under the ship by divers) that encloses the entire VSP unit and forms a watertight seal against the surrounding hull. Once the cofferdam is sealed a lift frame that sits on the deck above the ship s propeller room is used to support the removal of the VSP unit, which is then transferred by crane to a dockside support stand. The replacement task is essentially the reverse of the removal procedure. The procedure and equipment have been successfully used to replace VSP units both in and outside the UK, with timescales similar to those required for dry docking. This equipment provides additional flexibility for maintaining these ships when a dry dock is not readily available. Fouled blade before polishing Blade surface following polishing CONDITION MONITORING UMC have developed procedures for underwater visual inspection and NDE of VSP blades. The NDE capability, developed in conjunction with a leading British NDE specialist, uses the Alternating Current Field Measurement (ACFM) technique and an inspection probe designed specifically for VSP blade examination. BLADE POLISHING UMC s hydraulically powered polishing tool is perfectly suited to removing all forms of soft and hard marine fouling that typically forms on VSP blades. Polishing the blades to better than 1-micron CLA ensures that the efficiency of the VSP unit is maintained and additionally provides the ideal surface to support NDE and visual examination. The lift frame located on the deck & cofferdam installed in readiness for VSP removal

12 DESIGN & CONSULTANCY ENGINEERING DESIGN & MANUFACTURE UMC design and install an 11-ton cofferdam to support shell plating repairs THE ENGINEERING CONSULTANCY TEAM Our team of engineers and naval architects has a proven track record for providing effective designs whilst working to tight deadlines. Certified to ISO 9001:2000, UMC s Design and Consultancy Division, design and manufacture equipment and systems, including testing, certification, procedures and safety assessments to meet national and international standards. Man entry cofferdam for rudder plating repair Man entry cofferdam designed using 3D CAD software WORLDWIDE SERVICES Our engineering consultancy team has successfully designed and delivered projects including: Hull aperture blanks and large man entry cofferdams Handling equipment and sealing systems for stabilisers, rudders & propulsion systems Temporary seals for propulsion shafts and through hull penetrations including speed and depth transducers Installation of new and relocation of existing through hull fittings Customised hydraulic and pneumatic equipment for hull cleaning, propeller polishing and coating application Specialist cofferdams and equipment for offshore installations Manufactured Rudder probe Shaft seal arrangement

13 DESIGN & CONSULTANCY ENGINEERING & PROJECT MANAGEMENT UMC supervision of Voith Schneider Propeller Replacement NDT inspection of High Equivalent Steel in UMC s test tank. 3D Visualisation of 36m manentry cofferdam for floating dock. THE TEAM The engineering consultancy team combines naval architects and mechanical engineers with academic, professional and practical experience covering ship and equipment design, Finite Element Analysis (FEA), underwater ship husbandry, rudders and stabilisers, hydraulic and pneumatic systems, manufacturing, project management and management systems. Our Project managers deliver projects to cost and on time. They are qualified engineers with in-depth experience of marine engineering and manufacturing industries, combined with knowledge of ship and submarine systems, including equipment design, installation, commissioning and decommissioning, and operations on nuclear licensed sites. Our Services Include Research and Development into new equipment and procedures to support afloat maintenance requirements Guidance to Ship Design Authorities to optimise the design of new platforms utilising afloat maintenance techniques and procedures Production of documentation to support ship and submarine maintenance, including Defence Standards for UK MoD Development of specific techniques for replacement of hull mounted equipment Test and evaluation of materials and equipment used for afloat maintenance, including paints, adhesives and fillers Global Project Management services certified to ISO9001:2000 for afloat and marine engineering tasks. Design and installation of 11ton cofferdam Mounting underwater CCTV camera installed to the lifting keel for scientific research

14 DESIGN & CONSULTANCY ACOUSTIC CLADDING SYSTEMS Certified cladding applicator training at UMC A Dedicated SERVICE UMC s Design & Consultancy Division offer a comprehensive service for the application and upkeep of submarine and surface ship acoustic cladding systems. This service includes: Above and underwater survey of cladding fits Through life monitoring of cladding fits Cladding application and repair Application supervision Applicator training and certification UMC are world leaders in the development of cladding systems, with processes and technology developed in close consultation with the UK Ministry of Defence (MoD) now being transferred to UK MoD, preferred contractors and other navies. UMC has a proven track record in providing acoustic cladding services ranging from development of bespoke application techniques to application and repair on submarine and surface ships in dock, afloat, above and below the waterline. Cladding Survey Data Analysis UMC s Underwater cladding system Our Cladding Surveys Extensive Acoustic Cladding Survey Experience Cost effective surveys in dock and afloat, above and below the waterline Analysis of survey data Accurate reporting that enables effective costing by purchasers of tiling services UMC s extensive range of cladding equipment and technology Cladding application in dock

15 NEUTRALLY BUOYANT HULL APERTURE BLANKS Sea valves can be opened up inboard for survey, maintenance or repair whilst the vessel remains afloat. EFFICIENT The ability to blank off sea inlets and overboard discharges safely and quickly underwater is essential if costly delays or even unscheduled dockings are to be avoided. UMC blanks are supplied to ships in service and new builds. Our designs are also suitable for semi-submersible oilrigs and other offshore structures that cannot easily be brought to the surface. FPSOs that are sometimes on station for years rely on this kind of technology to enable them to remain on station. SAFE Thousands of our blanks have been supplied to literally hundreds of vessels and individual blanks have been fitted and refitted many times without one recorded failure. Our design incorporates a minimum safety factor of 4 and is approved by all the principal Classification Societies. All UMC hull blanks are quality checked to the highest standard. EASILY FITTED BY DIVERS The composition of each blank is varied to suit each individual hull aperture. A specialised computer programme computes the load on the blank from the dimensions and depth of the aperture beneath the waterline, and then designs a composite sandwich that is approximately neutrally buoyant whilst being rigid enough to withstand the differential pressure. This means that divers underwater can readily maneuver the largest of blanks. Provided the blanks are stored with reasonable care they have an infinite lifespan. We generally supply blanks in ship sets that are carried on board ready to be fitted, either as part of an inwater survey or to enable repairs to take place. However, individual blanks can be fabricated to deal with a particular repair requirement. MAGNASEAL Newly introduced by UMC the MAGNASEAL device enables quick external blanking of all overboard discharge pipes up to 110mm diameter. One MAGNASEAL therefore can cover a range of overboards, reducing equipment required and subsequent costs. Overboard aperature blank Unblanked apertures UMC s manufacturing facility The Magnaseal

16 UNDERWATER HULL CLEANING EQUIPMENT THE MINI PAMPER VEHICLE Whatever coating is applied to your vessel conventional antifouling, low surface energy silicon coatings or no antifouling at all the Mini-Pamper hull cleaning vehicle will remove marine growth without damaging the substrate, subject to correct usage and brush selection. INNOVATIVE DESIGN The diagram below shows how the Mini-Pamper hull-cleaning machine is fitted with two counter-rotating brushes that create a suction force of several hundred kilograms on to the hull. If these brushes were allowed to operate without control they would abrade and damage the underlying surface. The onboard control mechanism incorporated into the brush mountings of Mini-Pamper counters this suction force and transfers the load on to the chassis. There is ample force to create a stable platform that can be driven and steered over the hull whilst the brushes glide over the surface without damage to the coating. Specifications Weight of vehicle in air 130kgs Weight in water slight positive buoyancy Length overall 1500mm Width overall 760mm Cleaning width 650mm Suction force approx. 400kgs Max speed 0.7 m/sec Max theoretical cleaning rate 1755m 2 per hr Practical achievable cleaning rate 1100m 2 per hr NB: Specification may change due to constant development of the vehicle.

17 UNDERWATER HULL CLEANING EQUIPMENT MINI PAMPER BRUSHES (350mm diameter) Whatever coating is applied to your vessel conventional antifouling, low surface energy silicon coatings or no antifouling at all the MINI-PAMPER hull cleaning vehicle will remove marine growth without damaging the substrate, subject to correct usage and brush selection. POLYESTER BRISTLE BRUSH (Heavy Duty) POLYESTER BRISTLE BRUSH (Light Duty) 4 rows of hard plastic bristles, for removing heavy slime and weed. UMC ordering number rows of soft plastic bristles for removing light to medium slime and weed. UMC ordering number NEW SILICON COATING CLEANING BRUSH STAINLESS STEEL WIRE BRUSH This brush has been developed to remove marine fouling from low surface energy coatings, without causing coating damage. UMC ordering number (RH), (LH) 5 rows of stainless steel wire for removing medium to heavy slime and weed and infant shell growth. UMC ordering number TWISTED WIRE BRUSH COACH BOLT BRUSH 3 rows of twisted wire for removing medium to heavy shell growth. UMC ordering number rows of coach bolts for removing very heavy shell growth. UMC ordering number 01146

18 UNDERWATER HULL CLEANING EQUIPMENT PEE-JAY TWIN BRUSH MACHINE Various brush syles for removing marine fouling Ideal entry-level hull cleaning system. UNIQUE Mobility A unique and compact diver held twin brush machine that has forward and backward assist technology. The machine complements the Mini Pamper hull cleaning machine, for cleaning rudders etc, but equally capable of cleaning entire ships hulls. Easy to mobilise and can be powered by UMC s LD50 Power pack (see separate data sheet). Ideal entry level hull cleaning system. Specifications Dimensions without brushes Weight in air (with plastic bristle brushes) Weight in water (with plastic bristle brushes) 670mm wide x 450mm long x 230mm high 23kg 3.5kg buoyant Hydraulic 0-40lpm requirement at 155 Brush diameter Cleaning width (depending on brush type) Cleaning rate (depending on conditions) 260 to 320mm 520 to 630mm 800m 2 per hour NB: Specification may change due to constant development of the vehicle. For information on the Twin Brush Hull Cleaning Machine please contact Equipment Sales at UMC. The twin brush cleaning machine in use UMC s LD50 hydraulic compressor provides the ideal power source for the Pee-Jay hull cleaning machine

19 UNDERWATER HULL CLEANING EQUIPMENT PEE-JAY BRUSHES (280mm diameter) Ideal entry-level hull cleaning system. POLYESTER BRISTLE BRUSH STAINLESS STEEL WIRE BRUSH 4 rows of soft plastic bristles for removing light to medium slime and weed. UMC ordering number rows of stainless steel wire for removing medium to heavy slime and weed and infant shell growth. UMC ordering number TWISTED WIRE BRUSH COACH BOLT BRUSH 3 rows of twisted wire for removing medium to heavy shell growth. UMC ordering number rows of coach bolts for removing very heavy shell growth. UMC ordering number 01102

20 Founded in 1972, UMC has built a worldwide rapid response network of services specialising in waterborne repair and maintenance technology for commercial, naval and offshore vessels. These innovative products and services reduce the need to dry dock, allowing vessels to remain at sea, earning and operating. Underwater engineering services include platform repairs, equipment installation/replacement, stern seal replacement and repairs, wet welding, coating and adhesive application, condition monitoring and survey. The Design & Consultancy Division provides project management services and turnkey solutions for marine engineering tasks. All project managers are qualified engineers with experience in ship and submarine systems, equipment design, installation, commissioning and decommissioning. Worldwide Rapid Response For Inwater Maintenance & Throughlife Waterborne Support The Manufacturing Division design and fabricate customised blanks and cofferdams. Other groundbreaking products include newgeneration hull and propeller cleaning equipment, and paints and adhesives for underwater application. UMC International holds a current ISO 9001:2000 Certificate. UMC is formally accredited by leading industry bodies and associations including: Lloyds Register of Shipping American Bureau of Shipping Det Norske Veritas Bureau Veritas Germanischer Lloyd RINA Indian Register of Shipping Class NK International Naval Surveys Bureau Vessel images have been kindly approved for use by the following: P&O Cruises Limited; Crown copyright/mod. Reproduced with the permission of the controller of Her Majesty s Stationery Office.