Customer Magazine ISSUE 4 (16) 2014 - Remontowa€¦ · Pages 6 - 7 Shoreway familiarised ......

Pioneering propulsionconversionPage 3 - 5Photo: Media4Sea

Customer Magazine ISSUE 4 (16) 2014

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The fourth dredger from Royal Boskalis Westminster has been serviced in 2014

Pages 6 - 7

Shoreway familiarised with our docks

For sustainable ferry trafic...Hybrid propelled Deutschland got its scrubber installation at Remontowa

Pages 8 - 11

The Year 2014 in reviewFour various projects - four different challenges from the offshore oil & gas and wind markets

Pages 15 - 18

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remontowarepair&conversion

customermagazineISSUE 4(16) December 2014

The 2015 year has finally begun. The new emission control regulations af-fecting many shipowners and fleet op-erators have come into force.

From January 2015, all vessels in the Emission Controlled Area (ECA) of the Baltic Sea, North Sea, English Channel and waters 200 nautical miles from the coast of US and Canada, need to re-duce their sulphur emissions to 0,1%. Vessels are required to use either a distillate, an alternate fuel or install a scrubber that removes sulphur from the exhaust after combustion.

Many shipowners and equipment manufacturers have been prepared for change in Emission Controlled Areas by 2015, by testing various solutions in order to implement them in 2015. And Remontowa S.A. is also participating in these efforts helping vessel operators to comply with the ECA regulations. The two most recent examples are Scandlines hybrid ferries and Stena Line’s first vessel to run on methanol. Scandlines is a widely known Europe-an operator, which in 2013 introduced the hybrid propulsion system which is now being installed on board its dou-ble-ended ferries on the route Putt-garden-Rødby. The system combines traditional diesel propulsion (with ex-haust fumes cleaned with scrubber technology) with electric battery pow-er, being a significant milestone since it represents the world’s largest ever hybrid propulsion marine battery pack.

Especially during port times, excess energy produced can be stored in bat-teries on board the ferries. When more energy is needed than the diesel gen-erator can provide, the necessary en-ergy can be tapped from the system. When less energy is needed the sys-tem is filled up with surplus energy. This ensures that the diesel engine al-ways operates at an optimal load.

Apart from optimizing the output of the ships’ engines, the number of op-erating diesel generators can be mini-mised to one by using the hybrid sys-tem. This way it is only necessary to install a scrubber on one of the ferry’s four engines in order to meet the new IMO requirements (the three remain-ing engines run on gas oil, which con-tains only 0,1 per cent sulphur and consequently does not require clean-ing in order to meet MARPOL require-ments).

When the ferries operate on diesel engines, the scrubber technology has been chosen. At Remontowa, we have installed the scrubber systems on the Scandlines operated Schleswig-Hol-stein (in 2013) and Deutschland hy-brid ferries (2014 - see details on pag-es 8-11).

Stena Line has found an alternative solution. The company has decided to convert the Stena Germanica ro-pax ferry to run on methanol (see details on pages 3-5).

According to the presentation by Per Westling CEO of Stena RoRo AB on Interferry Conference Malta October 2013, this modern fuel is created by adding one oxygen atom to natural gas (Methane CH 4). Methanol is used as a fuel already today but in limited areas (e.g. monster truck racing, speedway, aerobatics etc.). It is a liquid at room temperature and needs neither cryo-genic nor pressure tanks. It can be also stored onboard and ashore in similar tanks as oil products and can be trans-ported in regular product tankers. And what is more, a vessel conversion to methanol is considerably less expen-sive than conversion to LNG - as Per Westling emphasizes.

Stena Germanica is going to have its four engines converted to methanol. The vessel was expected to enter our yard in January 2015.

2015 - the Year of change

Remontowa Repair & Conversion is a quarterly customer magazine of Remontowa Shiprepair Yard, member of Remontowa Holding S.A. Publisher: Temat Ltd., Na Ostrowiu 1, 80-958 Gdańsk, Poland.Editor-in-Chief: Grzegorz Landowski. Phone: +48 58 307 17 90, e-mail: [email protected] content of the magazine (with the exception of photos) may by reproduced provided the source.

3 Pioneering propulsion conversion

8 For sustainable ferry trafic...

15 The Year 2014 in review

13 Half-year preparations for a five-hour operation

19 Picture with a huge platform

6 Shoreway familiarised with our docks

12 Ships with names of stars

Stena Germanica to run on modern fuel - methanol

Hybrid propelled Deutschland got its scrubber installation at Remontowa

Representatives of renowned Canadian Owner arrived to see the shipyards of Remontowa Holding


Synergas of Napoli brought its gas carrier to Remontowa for the first time

Four various projects - four different challenges from the offshore oil & gas and wind markets

Challenging tasks handled by Production Technology Office in FPF-1 conversion project

contentseditorial conversion

Grzegorz LandowskiEditor-in-Chief

Pioneering propulsionconversion

Stena Germanica to run on modern fuel - methanol

One of the world’s biggest ferry companies, Stena Line, becomes the first operator in the world to run a large 1,500 passenger ferry on methanol, drastically reducing emissions compared to today’s standard fuel, after completion of what will be the first such ship conversion to be undertaken, according to the company’s official news release.

Pioneering propulsionconversionPage 3 - 5Photo: Media4Sea

Customer Magazine ISSUE 4 (16) 2014

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Pages 6 - 7

Shoreway familiarised with our docks

For sustainable ferry trafic...Hybrid propelled Deutschland got its scrubber installation at Remontowa

Pages 8 - 11

The Year 2014 in reviewFour various projects - four different challenges from the offshore oil & gas and wind markets

Pages 15 - 18

As revealed by Stena Line on November 19, 2014, the ferry operator has decid-ed to convert one of its ships sailing between Gothenburg and Kiel to methanol propulsion. The 240 meter long ferry Stena Germanica (ex Stena Hollandica) will be the first large ship in the world to run on methanol in early 2015. The project is done in co-operation with the leading engine manufacturer Wärtsilä, the port of Gothenburg, the port of Kiel and the world’s largest methanol producer and sup-plier Methanex Corporation.

Stena Germanica departing from Remontowa S.A.

after completion of its “conventional” conversion in 2011. Photo: Media4Sea


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Stena Germanica will be converted at the Remontowa Shiprepair Yard, mem-ber of Remontowa Holding in Gdansk, Poland starting January 2015. The process is expected to take six weeks and is financially supported by the EU “Motorways of the Seas” initiative. To-tal project cost is about Euro 22 million (USD 27.5 m) and the ship is expect to return to operation in March 2015.

- At Stena Line we are extremely proud of contributing to the develop-ment of our industry. Our focus has al-ways been on innovation for the benefit of both customers and society at large and this is a prime example when this goes hand in hand. We are constantly evaluating different fuels for the future and to be first in the world with a meth-anol conversion is a big step towards sustainable transportation. The project has been possible thanks to the great

teamwork and collaboration between our technical staff, Wärtsilä and Meth-anex - says Carl-Johan Hagman, CEO of Stena Line.

The vessel will be converted to run on methanol, using an engine conver-sion kit and ship application supplied and developed by Wärtsilä in co-oper-ation with Stena Teknik. The kit will al-low the vessel to operate in dual-fuel configuration using methanol supplied by Methanex, with MGO (Marine Gas Oil) as backup.

Methanol is a clear, colourless bio-degradable fuel that can be produced from natural gas, coal, “biomass” or even CO2. Methanol plays a key role in the energy sector as a clean and cost competitive alternative fuel and ener-gy resource. By using methanol the emissions of sulphur (SOx) will be re-duced about 99%, nitrogen (NOx) 60%, particles (PM) 95% and carbon diox-ide (CO2) 25% compared with today’s widely used fuel (HFO).

Methanol, having a similar emissions profile to LNG, has the potential to be an important fuel for the shipping in-dustry in the future. Although more ex-pensive to refine than LNG, methanol is liquid at ambient temperature, mak-ing it easier to handle and transport, and also allowing it to be stored for a greater length of time and requiring less infrastructure.

Since 2005 Stena Line has worked to reduce its environmental impact within its Energy Saving Programme, which has successfully reduced vessel ener-gy consumption by on average 2,5 % every year.

- It is a project that involved several companies in the Stena Sphere, which makes it very special for us. Stena Line, Stena Teknik, Stena Bulk, Stena RoRo and Stena Oil have all been involved with their respective areas of exper-tise. This internal collaboration made this possible. Naturally, adapting and converting Stena Lines fleet of some

40 ferries to the new regulations in the near future is a very tough task which will both take time, effort and money - says Carl-Johan Hagman.

From early 2015, vessels in the area around the Baltic and North Sea, known as the SECA area, will have to use fuel with very low sulphur content of 0.1% (today the fuel restriction is 1.0%). Most common is MGO which will be about 40-50% higher in price compared to HFO (heavy fuel oil) which is being used today. In parallel with the change to low-sulphur oils, Stena Line is running a number of projects to look at other al-ternative fuels and different techniques for emission purification such as LNG, electric propulsion and scrubbers.

- Due to our size we have a broad perspective on handling the new sul-phur regulations and it is likely we will use some different types of solutions in the coming years. However, based on the results of the methanol project we are intending to convert additional fer-

ries - says Stena Line CEO Carl-Johan Hagman.

Ships of the renowned Swedish based ferry operator Stena Line are not a rare sight at Remontowa. So it was the case with Stena Germanica. The ship has already been convert-ed at Remontowa. It was at the turn of 2010 and 2011 and involved structural, rather than machinery modifications. At that time it was a wide scope, but “con-ventional” conversion. We added 100 passenger cabins in new superstruc-ture section, we refurbished and up-graded public spaces, including some restaurants and bars. This time, how-ever, much more complex, in technical terms, if not “experimental”, modifica-tion works await us.

The project may be regarded as a pi-oneering one, given the size of the ship and propulsion plant in combination with innovative technology, previously used only in tests and in small scale. Following the conversion the ship will

conform to new stringent EU and IMO environmental regulations.

The ship has been scheduled to en-ter Remontowa during January 2015, however already several weeks earli-er all possible preparations had com-menced at the yard, including pre-fabrication of structural, systems or machinery parts to be used in conver-sion. It involves construction and out-fitting of new compartment, i.e. meth-anol pump room, installation of high pressure, double walled, methanol fuel feed piping, etc.

As the aim of conversion is, general-ly, improvement of operational perfor-mance, including cutting the fuel costs, additional measures - besides modifi-cation to propulsion system itself - are taken to optimize the fuel consumption. The hull will become more hydrody-namically effective, contributing to fuel costs cutting, owing to modification of the bulbous bow (replacement with a new shape bulb section). �

In 2011, the new part of superstructure (new deck) had been installed, which extended the passenger spaces with both cabins and public spaces onboard Stena Germanica.Photo: Media4Sea

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Shoreway familiarisedwith our docks


Willem van Oranje (12,000 cu m capacity), Barent Zanen (8,116 cu m), Crestway (5,600 m sześc.) are just a few of sea-going dredgers operated by Dutch company Royal Boskalis Westminster, that have been thoroughly repaired and serviced at Remontowa S.A. with a varied scopes of works specified. This list may now be amended with another entry, namely the trailing suction hopper dredger Shoreway.

Shoreway, delivered in 2008 from IHC Mer-wede yard in Sliedrecht, is a 5,600 cu m trail-ing suction hopper dredger - first of two medi-um-sized hoppers built in this series. Her sister ship is the Crestway. Both ships are 97.5 m long. They are used in global Boskalis dredg-ing operations, and they have been specially designed for dredging and the transportation of sand and sludge. They are ideal both for work-ing in shallow waters and for the maintenance of harbours, beach replenishment and land rec-lamation projects. Shoreway, similarly to Crest-way, features design with a high level of ver-satility. During the design phase, the emphasis was put on keeping the weight of the vessel relatively low, while maximising hopper capac-ity. The specialist ship also features: mechani-cal driven dredge pump through maximum two main engines, degassing system applied, three main engines installed, two being dedicated for propulsion and the third driving the dredge pump during trailing, suction tube installed on port side, accommodation situated on fore ship and engine room and pump room situated aft. The Bureau Veritas classed vessel is 97.50 m long over all, 21.60 m wide, 7.60 m deep, draw-ing 3.90 m when empty, 5.70 m to international load line and 7.10 m to dredging load line and features gross tonnage of 5,005, carrying ca-pacity (D.W.) of 8,350 t and hopper capacity equalling to 5,600 cu m, suction pipe with a di-ameter 1,000 mm, max. dredging depth of 33 m, sailing speed loaded up to 13.0 kn, total in-stalled power of 6,700 kW (3 x 2,025 kW + 1 x 520 kW + 1 x 105 kW) as well as discharge sys-tems in for of bottom doors, pump ashore sys-tem and rainbow installation.

This dredger was hosted and serviced at our shipyard from October 31 till December 2, 2014. The ship spent relatively long time (26 days) in dock. Of the extensive range of works specified, probably the single biggest item was modification to the dredged material pump ashore system - additional pump has been in-stalled at Remontowa, that is meant to boost the effectiveness of output transport to shore. This implicated connection of the pump, piping works, electrical works, construction of foun-

dation structure for the pump, installation of electric motors and construction of a new sea chest. Main sections of piping, coated with spe-cial paint, were the Owners’ supply, while pipe end parts had been prefabricated at our yard. At the yard temporary dummy pipe end parts have been installed, while the actual, perma-nent parts, manufactured at Remontowa, sup-plied to the Netherlands will be installed later by the Owner (replacing the dummy piping parts).

A wide range of maintenance and painting works has also been specified. These covered hopper coamings, davits, funnel stack, venti-lation ducts, 3,400 sq m of the hull surface, some 2,500 sq m of accommodation block compartments and travelling gantry crane among other items. Some minor hull and steelworks have been performed on bottom hopper doors and piping works - in hopper. Suction pipe head has also been repaired. Furthermore, some steelwork and exhaust pipe modifications have been carried out in funnel stack, Owners’ logo has been replaced on funnel and on navigation deck, besides hy-draulic pumps and ventilation and air-condi-tioning fans overhauls, not to mention numer-ous minor repairs and modifications.

Boskalis (Bos & Kalis) was created in 1910 by a group of families. In between the two wars, Boskalis contributed to the famous Zuiderzee project (a complete flood protection system for The Netherlands). In 1933, Boskalis partnered with the Westminster Dredging Company, which opened new business opportunities worldwide. Today, Royal Boskalis Westminster nv is an in-ternational group with a leading position in the world market for dredging services. Its core ac-tivities are the construction and maintenance of ports and waterways, land reclamation, coastal defence and riverbank protection. The compa-ny holds ten home market positions in and out-side Europe and targets all market segments in the dredging industry. It also has positions in strategic partnerships in the Middle East (Archi-rodon) and in offshore services (Lamnalco).

Boskalis has a versatile fleet of over 300 units and operates in over 50 countries across five continents. Many of these ships, especially dredgers of various types have been serviced at Remontowa to date. Shoreway is the fourth unit (after Gateway, Crestway and Willem van Oranje) repaired in 2014 and also the fourth one (after Gateway, Shoalway and Crestway) with the “way” in a name... �

A “family” picture with the Shoreway dredger inside a dock at Remontowa.Photo: Jerzy Uklejewski

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For sustainableferry trafic...

Hybrid propelled Deutschland got its scrubber installation at Remontowa

Given the number of projects completed already and early market entry, with leading or even pioneering position, the installation of scrubber systems may be regarded as one of the specialties of Remontowa.

The Gdansk based yard has retrofit-ted numerous ships with scrubbers so far, not only ferries / passenger ships, but also cargo ro-ro’s, an LPG tanker and multipurpose cargo vessels. As we were going to press mid-December 2014, Remontowa had been expected with further orders in hand to execute scrubber retrofitting projects on at least 12 ships until January 2015.

Recently the scrubber system has been installed onboard large German double-ended ferry Deutschland.

The 1997, Van der Giessen de Noord built ferry, along with its sis-tership Schleswig-Holstein (and two other, similar ferries) serves the busy Puttgarden-Rødby service. It accom-modates more than 360 cars and over 1000 passengers. The ferry makes a crossing of 18 km in roughly 45 min-

utes. Let us recall that Schleswig-Hol-stein has had its scrubber system in-stalled at Remontowa as well (the same season, a year before).

The two mentioned sister ferries, along with similar large double-end-ed ferries Prinsesse Benedikte and Prins Richard feature hybrid propul-sion system. For unrivalled environ-mentally friendly performance, these ferries combine hybrid technology

(featuring large scale batteries) with diesel-electric propulsion with ex-haust fumes cleaned with scrubber technology.

The battery power supply system on-board a ship like Prinsesse Benedikte or Deutschland equals approximate-ly 600 hybrid cars and can propel the 6,600 ton lightweight ferry for about 30 minutes without diesel fuel and at a speed of 14 knots. To ensure envi-

Deutschland entering Remontowa for scrubbers installation.Photo: Jerzy Uklejewski

The ferry in a dock during retrofitting. Scrubber in order to be installed in funnel stack starboard side

was lifted up by floating crane REM 220.Photo: Jerzy Uklejewski

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ronmentally friendly operation of these ferries outside mentioned “battery op-eration” time windows, when the ferries operate on diesel engines, the scrub-ber technology has been chosen.

The scrubber systems on Schleswig-Holstein (in 2013) and on Deutschland (in 2014) were installed at Remontowa. The key parts of Deutschalnd’s scrubber system have been installed in funnel stack starboard side and adjacent deckhouse fabri-cated at Remontowa during the ship’s visit to Gdansk, late fall 2014. To facil-itate shortening of shipyard stay peri-od for the ferry (similarly to the earlier case of scrubber system installation on Schleswig-Holstein), prefabrication and preassembly of a new funnel and part of engine casing to house new exhaust gas cleaning system had be-

gun prior to the Deutschland’s arrival to Remontowa S.A.

However, installing the scrubber sys-tem was not the only task Remontowa was entrusted with during recent stay of Deutschland in Gdansk. Among jobs worth mentioning, there was a replace-ment of the generating set with a new, bigger one. This called for de-installa-tion, complex transport through deck no. 3, temporary transport hatch on deck, reinstallation, connection of sys-tems, placing on foundation vibration dampers, regulation, aligning of gener-ator shaft, etc.

The range of works specified also in-cluded some steelwork, including re-placement of 10 fragments of steel fen-dering of varied length on starboard side and one 15 m long section port side. Besides temporary hatch in deck

for transport of generating set, tempo-rary 3 x× 3 m side port was cut starboard side for transport of a tank.

Repairs have been carried out on azimuthing main propulsion thrusters, seawater pumps, tanks have been cleaned, engine room fans have been dismantled and taken away for over-haul in workshop, sea chest valves and fittings have been overhauled as well, along with potable water system. Hydraulic system piping has been re-placed with new one as well. Mean-while, the owners, have been carrying out refurbishment works in passenger public spaces (shop, restaurant) with own contractors.

The hybrid propulsion system on the route Puttgarden-Rødby, combined with scrubber technology for diesel op-eration periods of ferries, is a key el-

ement of the Scandlines strategy for more sustainable ferry traffic and is a part of a series of large investments in environmental technologies. By the end of the period 2013-2015, Scand-lines will have invested more than EUR 25 million in sustainable technologies on the route Puttgarden-Rødby.

Scandlines was founded in 1998 and is one of the largest ferry operators in Europe. On three short distance routes between Germany, Denmark and Swe-den with high frequency and large ca-pacity, the company provides efficient and reliable transportation services to both passengers and freight custom-ers. In 2013, Scandlines transported 11 million passengers, 2.5 million cars and 0.7 million cargo units on their routes Puttgarden-Rødby, Rostock-Gedser and Helsingør-Helsingborg. �

The scrubber was covered by a special steel casing.Photo: Jerzy Uklejewski

Deutschland departing from Remontowa with scrubbers installed and a “hybrid ferry” sign painted on the starboard side.Photo: Adam Graczyk

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Ships with names of stars

Synergas of Napoli brought its gas carrier to Remontowa for the first time

Italian company Synergas of Napoli is the owner and operator of several dozens of gas tankers. Carrying LPG, ethylene and other cargoes they mainly sail into The Mediterranean, The North Sea, not omitting The Baltic Sea either.

The ships operated by Synergas are mostly equipped with self-supporting, cylindrical or bi-lobe, thermally insulat-ed tanks. Their cargo containment sys-tem is mostly of semi-refrigerated type and most of them are able not only to carry LPG, but also ethylene and some other cargoes.

The ships in Italian company’s fleet are bearing names of stars, preceded with “Syn” prefix, to be associated with shipowners’ name (Synergas). There-fore one may meet such ships as Syn Acrab, Syn Atlas, Syn Zube, Syn Mark-ab or Syn Antares - one of the latest addition to fleet, delivered earlier this year by neighbouring Gdansk Ship-yard. However, the ship visited our shipyard prior to delivery, last year,

when, to the order of its newbuilding yard, Remontowa docked Syn Antar-es (123.2 m long) for 10 days, install-ing complete steering system (steering gear, rudder stock, rudder plate). We also performed maintenance works on underwater hull.

Recently, Synergas brought one of their ships to Remontowa for repairs for the first time. On October 7, the Syn Zau-ra LPG tanker arrived to our shipyard to undergo a 5 year survey and repairs.

The Bureau Veritas classed ship, built in 2000 at Cantieri Navale Di Pesaro, was launched as Val Badia and was trading under this name un-til 2006. The LPG tanker, of 4174 dwt capacity, 95.2 m long, 16.4 m wide and drawing 5.3 m, flies the Italian flag and is homeported in Augusta.

In dock, the whole hull was cleaned and painted, including double anti-foul-ing coating on underwater part of hull, while the whole propeller got coated with silicone paint, meant to reduce fuel consumption.

Of the wide range of works specified, it is worth to mention tunnel thruster maintenance, replacement of sacrifi-cial anodes, works on rudder system and stern tube, maintenance of an-chors and anchor chains, some steel replacement work, exhaust gas econ-omizer, replacement of piping on deck, main engine (MAN 9L) overhaul, over-haul of eight electric motors taken away to workshop, overhaul of 22 suc-tion and discharge valves and nine fuel pumps. One of the ballast tanks has been modified as well. �

Syn Zaura while being painted in a dock.Photo: Jerzy Uklejewski

Representatives of Remontowa S.A. (on the right) and its subcontractor (on the left) with Domenico Lubrano Lavadera - superintendent at Synergas Napoli.Photo: Jerzy Uklejewski

Half-year preparationsfor a five-hour operation

Challenging tasks handled by Production Technology Office in FPF-1 conversion project

The work of the Remontowa Shiprepair Yard’s Production Technology Office on the project of FPF-1 platform conversion is obviously just a fraction in execution of this prestigious contract. Just a fraction, but the key, essential part as well.

This may be judged from an example of complex operation of transport of the suspended process modules, sev-eral dozen tons each, that have been installed just under the deck of the semi-submersible platform. Precise planning and safe execution of these operations are the result of solutions and procedures conceived by employ-ees of the Production Technology Of-fice led by Grzegorz Oracz.

– Production Technology Office prepares production technology pro-cedures of the biggest and most com-plex shipyard’s projects for years now – Andrzej Stryjewski, technical director explains. – These prepara-tions commence already at the stage of analysing of owner’s project spec-ification and contracting and refer to technical feasibility assessment of planned works and production pro-cesses.

After signing of the contract, the de-velopment of production technology documentation phase commences. What is production technology? For example for hull construction, it means deciding on block division of the hull, conceiving the process of prefabrica-tion, and then of assembly, with spe-cial consideration of transport opera-tions – as Andrzej Stryjewski, explains to make things short.

In case of FPF-1 semi-sub platform, the complexity of the project is excep-tional, similarly to the size of the object itself.

– Indeed, conversion of this platform is an extraordinary challenge for our Production Technology Office – admits Grzegorz Oracz.

One of the good examples for that is the transport of suspended process or other modules, as it is also a spectacu-lar production event. It was a huge re-sponsibility to ensure the swift execu-tion of the operation. Not least because of the multi-million dollar cost of moved items of equipment.

As it has come out for the Owners and their designers that not all of pro-duction system would fit on the main deck, it was decided to plan and de-sign four process modules, weighing 230 tons in total, as suspended ones, installed underneath the semi-sub’s deck. Altogether six modules had to be transported and installed below the semi-sub’ s deck structure, ranging from 20 to some 40 ton in weight. They were fully outfitted themselves and par-tially accompanied by piping installa-tions.

Remontowa’s Production Technol-ogy Office was therefore expected to conceive and present the concept for transport of the heavy and expensive modules to their place of installation or

suspension. The core of resulting idea was that the process modules would be fully equipped when being installed.

– Several various options of transport path and mode have been considered – Grzegorz Oracz explains. – That was really a pioneering job for us. Eventu-ally we decided to use one of the two Remontowa’s heavy lift submersible barges, namely Rem Lift 25 000, as a kind of platform, from which the mod-ules were skidded onto the structure of the semi-sub and then onto the place of suspension. Then, the vertical trans-port followed, executed in co-operation with Italian specialist Fiagioli, having a specialist heavy-lift equipment at its disposal, especially their system, using the hydraulic cylinders, named Strand Jack.

Everything went as planned and ex-pected, our ideas proved themselves in practise, which is an additional source of satisfaction.

How the operation looked like in de-tail?... In initial phase, prefabricat-ed transport bed structures, on which the sections had to be skidded, were placed inside (between semi-sub col-umns, on bracings) with use of heavy caterpillar track crane operated on deck of Rem Lift 25 000. Then the out-fitted modules have been transport-ed onto a support structure on deck of Rem Lift 25 000 with use of Remontow’a

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own sheerleg floating crane Rem 220. The support structure on the barge was then connected with semi-sub’s brac-ings supported transport bed rails and the modules were skidded “inside”, a distance of some 25 m, with use of trol-leys. When “inside” (under the deck of the semi-sub), the heavy modules had the system of wire ropes and Strand Jacks attached. The actual lifting oper-ation took some five hours, of which the vertical transport, some 23 m high, con-sumed two and a half hours and the re-mainder was devoted to fixing and fas-tening the modules in their final position, suspended under the semi-sub deck.

Uniqueness and extend of complexi-ty of the module lifting operation is well depicted by the fact, that six month of work of several engineers, directly en-gaged in preparing the production tech-

nology documentation, carrying out consultations, simulations and strength calculations, preceded just 5 hours of actual operation. Additional challenge was the necessity to ensure safe work environment in these uncommon cir-cumstances of work in height.

It was crucial to lift each module evenly to reduce any additional struc-tural tensions resulting from torsional strain.

Coordination was the key. Not only pure technical operations during lift-ing, but also the proper sequence of production and outfitting of modules have been the key factors in success-ful completion of the task.

After installing the suspended mod-ules, transport and installation of he-lideck and its foundations follows, total-ling 100 ton, and a telecommunication

antennas mast, 27.5 high, just to men-tion some of the larger structures. For these operations, the production tech-nology procedures have also been de-veloped by the office led by Grzegorz Oracz. At some stages as much as 80 percent of the Production Technolo-gy Office’s man-hour output had been dedicated to FPF-1 project. Recently it has been around 50 percent share. Large shipyard needs production tech-nology conceived also for other proj-ects on stream.

– Ideas, solutions, documentation conceived and developed at Remon-towa’a Production Technology Office is a significant intellectual property of the yard. We have to protect it, while ex-panding the Office itself reasonably. It pays - concludes director Andrzej Stry-jewski. �

Transporting of the suspended process module, to its destination for installation underneath the FPF-1 semi-submersible platform.Photo: Cezary Gierszewski/5xMedia

The Year 2014in review

Various projects - different challenges from the offshore oil & gas and wind markets

The Prosafe operated accommodation and workshop unit arrived to Remontowa S.A. late November 2013, to undergo re-pairs, maintenance and upgrade. It was actually the fourth unit serviced by Remontowa for Prosafe, with the previous being: Safe Caledonia, Safe Esbjerg and Safe Bristolia. Remontowa has several repair, upgrade and conversion projects of drilling and production rigs of other operators in its reference list as well.

The focus and aims of the Safe Caledonia project were, amongst others, to increase her mooring capability (by replacing 12 mooring winches and anchor cables), replace the original deck cranes and refurbish the cabins. Berth cabin modules have been replaced with new ones, hulls and columns maintenance and painting have been performed with the unit lifted up on the shipyard’s own heavy-lift barge REM Lift 25 000. As most of the extensive range of works, mentioned above, had been completed - the undocking of the unit went smoothly on a fine, sunny day of March 8, 2014.

However, the platform didn’t depart from the yard immediately afterwards. The completion of repair and upgrade works were on the agenda after undocking, not to mention test-runs and activation of the unit’s systems. Also heeling (stability) tests were executed prior to Safe Scandinavia departure (on the picture above).

The works were carried out by the shipyard through mechanical completion procedure till full commissioning. Remontowa SA delivered the converted rig as well as the full documentation (mechanical completion documents) reflecting the actu-al state of the floating unit after completion of the project. The platform departed Remontowa SA on 13th of April 2014. �

The Safe Scandinavia acconmodation unit was also retrofitted at Remontowa in 2014.Photo: Remontowa S.A.

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ISSUE 4(16) December 2014 17customermagazine

offshore

But offshore industry is not only about drilling, production or support rigs. This sector also employs specialist tankers able to load oil at sea, at offshore oil fields - the ships known as shuttle tankers.

Overseas Tampa, one of the 46,666 dwt “Veteran” Class (MT-46 design) Jones Act products tankers built by Aker Phila-delphia Shipyard and operated by OSG Ship Management (OSG) was successfully converted to a shuttle tanker at Gdan-sk Shiprepair Yard Remontowa SA, member of Remontowa Holding, thus proved that significant high-tech conversions, allowing for change of the Jones Act ship’s functionality and widening its deployment opportunities are possible abroad. For Remontowa, with a rich reference list of tanker to shuttle tanker conversions, so far - mainly for Nordic customers, the Overseas Tampa job also means getting a foothold on a new market for similar conversions. This one was the first one to be carried out for the Owner outside Europe.

When the ship was berthed at Remontowa’s quay on June 10, 2014, the yard had already had prefabrication works well advanced, so some components and structures had been waiting for the ship, when it arrived. For example the thruster compartment was prefabricated and outfitted in some 80 percent at the time of the ship’s arrival. Then it was installed on the ship in one pre-outfitted section. The technology adopted and project schedule regime allowed to complete the job within contractual timeframe. The ship left Remontowa at the end of July, 2014.

The shipyard, experienced in conventional to shuttle tankers conversions, has passed the American exam, which was con-firmed by satisfied Owners. �

Overseas Tampa departing from Remontowa S.A. after completion of its conversion.Photo: Media4Sea

Remontowa is continuing progressively large conversion and upgrade project of the floating production semi-submersible platform FPF-1, operated by Petrofac - the 12fth offshore plat-form to be upgraded or converted at our yard (in this issue we mention another important milestone in the execution of the project - see details on pages 13 - 14).

The 82 m long, 75 m wide and some 30 m high platform, with a displacement of 26 639 tons and lightweight of some 14 000 tons, is a significant new task for Remontowa S.A., which has been entrusted by the Owner with the modification and modernization of the unit.

After stripping the semi-sub’s deck off existing equipment, docking (on Remontowa’s heavy-lift submersible barge) and the steelwork followed, including adding sponsons on rig’s stabilising columns. Then outfitting with complex processing systems commenced, which is now well advanced. Currently the heavy steelwork is in its final stage. Piping works have been well advanced and there were also preparations underway, for delivery-accep-tance tests (the so-called hydro tests), while the living quarters part of accommodation block / superstructure was in delivery-acceptance procedure. �

A night picture of the FPF-1 platform surrounded by numerous cranes with the Rem Lift 25 000 semi-submersible heavy lift unit...Photo: Remontowa S.A.

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offshore

Remontowa has some cable laying vessels repair, maintenance and conversion jobs in its reference list as well. The most recent one was a cable layer dedicated to offshore wind sector.

Siem Offshore Contractors sent the OSV Siddis Mariner to Remon-towa within the scope of preparations of the offshore execution of the Amrumbank West offshore wind farm project. The Amrumbank West offshore wind farm project (the wind farm is located in German part of the North Sea, some 35 km or 22 miles north of German island Hel-goland) involves the installation of 86 submarine cables providing the inner-array grid connecting the individual wind turbine generator foun-dation and the offshore substation.

In May 2014 Remontowa Shiprepair Yard S.A. completed conversion of OSV into cable layer. Siddis Mariner, built in 2011 featuring dead-weight of 4800 t, 88.1 m LOA, 19.6 m beam, 6.1 m draught and service speed of 15.5 knots is equipped with DP2 class dynamic positioning system.

Within the scope of conversion the ship has had the new decks in-stalled, where cable-laying equipment was installed, a few cranes in-stalled, structure strengthened in several places, as well as cable cradles and hydraulic piping connections installed. Tensioners, roller ways, slid frames, protection frames and winches have been installed. On the main deck the 40-ton container for cable has been installed, af-ter fabrication at the yard. Building foundations, connecting of cables and hydraulic piping was connected with installation of cable container. Submarine cable guide jib was installed as well. In total some 160 tons of steel structures have been installed onboard. �

Above: OSV Siddis Mariner upon its arrival. She was converted to a cable layer for the offshore wind sector. Below: After conversion. A lot of cable-laying equipment was installed on board the ship.Photo: Jerzy Uklejewski

events

Picture with ahuge platform

Representatives of renowned Canadian Owner arrived to see the shipyards of Remontowa Holding

Thanks to their journey to Poland, our guests from BC Ferries have become familiarised with the capacity and ongoing projects executed by Remontowa S.A.

Renowned North-American ferry oper-ator has recently ordered three modern ferries with LNG fuelled propulsion from Remontowa Shipbuilding. Mid-Octo-ber, Gdansk based yards visit of Mike Corrigan (President and Chief Exec-utive Officer BC Ferries), Mark Wil-son (Vice President, Engineering and Projects, BC Ferries), Donald Hayes (Chairman of the Board of Directors, BC Ferries) and Jack Lohman (presi-dent, BC Museum) commenced in the morning with Remontowa Shipbuilding yard tour. This is, where the new BC Ferries ships will be built. Honourable guests got acquainted with its produc-tion facilities and capabilities visiting the ship of kind similar to the ones or-dered by BC Ferries - a ferry currently under construction for Samso munici-pality in Denmark.

Following the tour at Remontowa Shipbuilding, the guests were host-ed by Piotr Soyka, the chairman of Remontowa Holding in his head-quarters localized at the Remontowa Shiprepair Yard. They could listen to presentation on services rendered by both shipyards within the Holding.

In the course of this meeting, Remon-towa S.A. was represented by CEO Ja-roslaw Flont, who introduced Canadian delegation to the yard’s capabilities in repairs and conversions and most in-teresting examples of work for the off-shore oil & gas industry.

Much attention was paid by the participants of the meeting to FPF-1 semi-sub platform, currently under conversion into floating production facility, as well as to conversions of tankers, among other matters. Cana-dian guests welcomed information on the Overseas Tampa tanker conver-sion to shuttle tanker with great inter-est and surprise, as the ships from the American market visit Europe-

an yards for repairs, maintenance or modifications very rarely, mainly due to Jones Act, the federal bill restrict-ing the possibilities of building, re-pairing or modifying US flagged and US waters operating ships outside the United States.

Also information on repairs and conversions of ferries, performed by Remontowa S.A., have been met with great interest. Among other themes, Jaroslaw Flont elaborated on instal-lations of scrubbers on several ro-ro ships and ferries as well as on pioneer-ing conversion of conventional propul-

sion of large ro-pax ferry Stena Ger-manica into methanol fuelled one.

He emphasized the quality and com-petitiveness of services offered by Remontowa S.A.

The Canadian guests were im-pressed with the number of the shiprepair yard’s direct employees and subcontractors. They mentioned they had not visited any shipyard neither in their country nor abroad of similar scale and providing such a large num-ber of workplaces.

Following the meeting and presenta-tions at Remontowa Holding, the Ca-

nadian guests toured Remontowa S.A., where they could see and learn on its production infrastructure, including floating docks, heavy-lift submersible barges, numerous ships under repairs and conversions and last, but not least, the FPF-1 semi-sub platform mentioned above. The honourable guests have ap-parently been impressed with what they saw, especially the size of the yard’s fa-cilities and variety of equipment, as well as the large scale of projects carried out, as one could often hear the words “amazing!”, “incredible!” and “huge!” during the tour. �

Canadian guests from BC Ferries (third, fourth and sixth from the left with Piotr Soyka among them) accompanied by the Remontowa Holding and both shipyards board members and directors during the tour around Remontowa S.A. Behind them - the FPF-1 platform.Photo: Grzegorz Landowski

Chief Executive OfficerMr. Jarosław Flont

Management Board Member (Production Affairs)Mr. Adam Ruszkowski

Management Board Member(Conversion and Offshore Affairs)Mr. Janusz Czajkowski

Management Board Member (Commercial Affairs)Mr. Zbigniew Andruszkiewicz

Offshore & Conversion Commercial Offices

Conversion, Upgrades, Modification Office: Director: Marek Sokołowski tel. (48 58) 307 11 67 fax (48 58) 307 28 67 mobile: (+48) 603 641 919 e-mail: [email protected]

Offshore and Special Constructions Projects Commercial Office Manager: Szymon Dołżonek tel. (48 58) 307 16 88 fax (48 58) 301 12 81 mobile: (+48) 502 160 470 e-mail: [email protected]

North& South Americas Conversions & Offshore Projects Manager: Bartłomiej Mucharski tel. (48 58) 307 25 45 mobile: (+48) 500 310 412 e-mail: [email protected]

Repair Commercial Offices

Americas Area: United States of America, Canada, South America. Manager: Andrzej Szadziński tel. (+48 58) 307 26 26 mobile (+48) 502 441 862 cell USA +1 (970) 390 8339 e-mail: [email protected]

British & Far East Area: United Kingdom, Irish Republic, Far EastManager: Dawid Piaskowski tel. (+48 58) 307 24 32 fax (+48 58) 301 12 81 mobile (+48) 515 087 260 e-mail: [email protected]

Western Europe Area: Germany, France, the Netherlands, Belgium, Switzerland. Manager: Piotr Kubicz tel. (+48 58) 307 19 64 fax (+48 58) 307 19 10 mobile (+48) 603 069 802 e-mail: [email protected]

Mediterranean Area: Greece, Cyprus, Turkey, Portugal, Spain, Croatia, Slovenia, Montenegro, Italy, Monaco, Algeria, Marocco. Manager: Marcin Seroka phone: (+48 58) 307 23 66 fax: (+48 58) 301 12 81

mobile (+48) 501 052 890 e-mail: [email protected]

Central Europe Area: Poland, the Czech Republic, Slovakia.Manager: Hubert Weiher tel. (+48 58) 307 16 23 fax (+48 58) 307 11 30 e-mail: [email protected]

Eastern Europe Area: Russia, Ukraine, Lithuania, Latvia, Estonia. Manager: Zygmunt Czapiewski tel. (+48 58) 307 26 53 fax (+48 58) 307 28 53 mobile (+48) 502 160 322 e-mail: [email protected]

Scandinavian Area: Norway, Denmark, Sweden, Finland, Iceland, Singapore. Manager: Marcin Mądrala tel. (+48 58) 307 23 01 fax (+48 58) 307 19 10 mobile (+48) 515 178 047 e-mail: [email protected]

Navy Units & Steel Structures:Manager: Arkadiusz Kieda tel. (+48 58) 307 14 26 fax (+48 58) 307 11 30 mobile (+48) 509 905 429

Customer Magazine ISSUE 4 (16) 2014 - Remontowa€¦ · Pages 6 - 7 Shoreway familiarised ......

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