Hydrex and AEGIR-Marine: performing underwater stern tube seals and propeller operations across the globe

ing out other repair or maintenance work on a stern tube seal assembly. Damaged propeller blades can be straightened with the Hydrex cold straightening machine or cropped if the damage is too extreme. has a very large stock of spare parts which are checked, rechecked and checked again by hand. Therefore they can guarantee availability of seals, spares and their engineers on very short notice. Combined with
AEGIR-Marine

ydrex and Dutch stern seal specialist AEGIR-Marine began working together in 2006, Hydrex as underwater specialists and AEGIRMarine as manufacturer-independent stern tube seal specialists. They collaborate to carry out in-situ underwater stern tube seal repairs developed by Hydrex for any manufacturer and type of seal.

Hydrex flexible mobdocks. These mobile mini drydocks are used to create a dry working environment underwater in which drydock conditions are simulated. Taking a vessel into an actual drydock is very disruptive to the ships operations and very expensive. Finding an available drydock is not easy; adapting a vessels schedule so that it can go to drydock is even more troublesome. Every day that a ship needs to go off hire means substantial losses, and the cost of

Hydrex has received full class acceptance from several major classification societies for underwater stern tube seal repairs.
Hydrexs large stock of equipment, the partnership can offer a fast response and be almost anywhere in the world within 24 hours. The customer gets an optimal service, in a short timeframe and at a good price. the drydock itself only adds to the negative financial aspect of docking. All this can be avoided by taking advantage of the in-water services offered by Hydrex with the full support of AEGIR-Marine. All Hydrex diver/technicians have been trained by AEGIR-Marine engineers as well as representatives of major seal manufacturers, to replace all types of seals. Our flexible mobdock allows us to do so underwater, making it unnecessary to drydock. These mobdocks are lightweight equipment, like all equipment used by Hydrex, so they can be transported anywhere in the world in a matter of days. Combined with the worldwide network of Hydrex offices and service stations this means that we can be at a location and ready to assist a vessel faster than one might think possible.

Using the Hydrex flexible mobdocks and the state of the art seal bonding equipment of AEGIR-Marine, fast response to any emergency call is guaranteed from the various workshop locations worldwide. Hydrex divers are regularly trained in the seal bonding procedures at the AEGIR-Marine facilities. Certified divers, assisted by an AEGIR-Marine service engineer, ensure the most reliable service available. Hydrex has now received full class acceptance from several major classification societies to perform underwater stern tube seal repairs in cooperation with AEGIR-Marine. This cooperation is beneficial for Hydrex, AEGIR and the customers of both companies. We can offer a full range of stern tube seal and propeller services, whether it entails the replacement of worn seals, providing a new running area for those seals or carry-

Underwater stern tube seals

Stern tube seal operations are performed with the use of the special

The Hydrex flexible mobdock allows Hydrex to create drydock like conditions underwater.

accustomed to solving such problems, our technical department worked out a procedure that enabled the repair team to carry out the job in the wet and after that install the mobdock, replace the seals and complete a full repair. If a vessel has an oil leak it is also often not allowed to sail on. The U.S. Coast Guard for instance has very strict policies concerning environmental risks and do not allow ships to sail

Hydrex diver/technician performing welding work on a rope guard.

After the flexible mobdock is installed around a stern tube seal assembly, our diver/technicians can enter the mobdock and start dismantling the assembly which can then be worked on in dry conditions. This is essential as bonding is not possible in the wet. During an operation the diver/technicians inside the mobdock remain in constant communication with the team leader and the AEGIR-Marine engineer on shore. The most common reason for a seal replacement is an oil leak. These are often caused by fishing nets or ropes that slip into the rope guard and get

Hydrex and ship owners.

AEGIR-Marine

can assist

A good example of this is the story of a 38,000 dwt bulk carrier that had suffered severe damage to her seal assembly. Hydrex was asked to do the repairs and replace the aft seals while the vessel was in Piombino, Italy. The rope guard was missing from the seal assembly and some of the stern tube flange bolts were seriously damaged, while others had broken off. The flange ring had mostly been scraped off, presumably by the rope guard before it had become completely

With the Hydrex cold straightening machine even severely bent blades can be straightened.

to a different location before the oil leak has been permanently fixed. Hydrex can make sure that a ship can sail again while keeping the loss of time to an absolute minimum.

Propeller modifications
A ship that has suffered damage to its propeller blades might have severe vibrations while sailing. The classification society might demand a repair before the vessel is allowed to sail on. By straightening the blades or cropping them, Hydrex can restore the propellers balance, resulting in a green light from the class for the vessel. Propeller blades can be straightened with the Hydrex cold straightening machine. After several years in service, a new version was put into use at the beginning of 2009. This enabled the Hydrex diver/technicians to straighten blades that have been bent over a bigger angle. The Hydrex research department is constantly looking into ways to develop this technique even further and at this very moment a new update is in its final testing stages.

The stern tube seal assembly of a bulk carrier had sustained damage that seemed too extensive to repair without going to drydock, but the Hydrex technical department worked out a procedure that enabled the repair team to carry out a full repair underwater.
tangled up in the seal assembly, causing damage to the seals. The running surface of the seals can also be out of limits, preventing a perfect sealing of the assembly from the outside and causing the oil leak. In some cases more severe damage is suffered, and replacing the seals or the running area is not enough. But even in these cases, which fortunately are very rare, detached. There was also a gap between the stern tube and the flange. It was clearly a complicated repair but our technical department worked out a procedure to carry out the work in-situ. Drydocking had initially appeared to be the only option for the ship owner. The stern tube seal assembly had sustained damage that seemed too extensive to repair underwater. Being

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HYDREX OFFICE FULLY OPERATIONAL AT THE STRAIT OF GIBRALTAR

ur Hydrex office in Algeciras, Spain offers a large variety of maintenance programs and repair works for ship owners and the offshore industry, both underwater and above water. Underwater maintenance services include hull cleanings, propeller polishings, class accepted surveys and tail-shaft wear down readings. Underwater repair work consists of propeller repairs, shell plating crack repairs, mobdock repairs, rudder pintle repairs and any type of welding work. Hydrex Spain also offers a wide range of above water operations including accomodation ladder repairs, anchor and chain work, cell guide repairs, crane repairs, hatch cover repairs and mechanical and engine works. Hydrex Spain is fully geared to carry out repairs at anchorage and in port. All operations are certified by the classification societies and are carried out by highly qualified divers and technicians all of which have extensive experience.

Hydrex Spain Poligono Industrial Palmones II Calle Dragaminas Nave N29 11370 Algeciras Spain
formance to as close to its optimum condition as possible and to balance it. This can help a vessel that is suffering loss of speed due to an out-of-balance propeller. Hydrex has been cropping propellers since 1985 and straightening them since 2000.

Phone: +34 956 675 049 (24/7) Fax: +34 956 921 914 E-mail: info@hydrex.es

If the blade is damaged too severely by ice of other floating debris, straightening is not feasible. In such cases cropping is the best option. This is often done with the support of AEGIRMarine Propulsion Service (AMPS), which focuses on propeller repairs and modifications. If it is decided that cropping is the only option, measurements are taken and used to calculate the exact radius of the area to be cropped. Both cropping and straightening are done to restore the propellers per-

communicate the exact dimensions and position of the damage to the Hydrex technical department supervising the operation. This is essential because the calculations need to be perfect to achieve an ideal result with the repair. For this reason team members work closely together with

Hydrex team members are not only divers, but have experience in dealing with all kinds of different situations and circumstances. They are trained to think with the people in the technical department and the AMPS engineers.
Prior to a propeller repair, a detailed underwater inspection is carried out by Hydrex diver/technicians who are certified to make a full assessment of the condition of the propeller and
AEGIR-Marine Propulsion. Hydrex team members are not only divers, but have experience in dealing with all kinds of different situations and circumstances. They are trained to think

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with the people in the technical department and the AMPS engineers. The Hydrex diver/technicians can assist in working out the best solution and have the skill and experience needed to implement the theoretical solutions that have been worked out. Hydrex does not only offer repair services, but can also help customers when they have the need for preventive or other special custom projects. At the end of 2010, preventive modifications were made in Bremerhaven to the blades of three ice-going sister vessels. When several vessels of this customer suffered damage and needed cropping after the 2009-2010 winter,

Hydrex and AEGIR-Marine: offering solutions together

This is what Hydrex does if a customer calls us for assistance: we work out a way of solving your problem.

AEGIR-Marine BV was founded in 2000 by Ruud Muis and Hans Dekker. Since then AEGIR developed into a midsize organization with facilities in The Netherlands, Shanghai and

If a customer calls us for assistance, we work out a way of solving their problem. This separates Hydrex from diving companies. We not only implement the solution, we have the know-how and experience to devise that solution in the first place.
This separates Hydrex from diving companies. We not only implement the solution, we have the know-how and experience to devise that solution in the first place. Hydrex has always strived to offer a wide range of services. The customer has always been the first concern. How can we make sure that he receives the best possible help in the shortest possible time? How can we take the problem out of his hands and solve it for him? Our cooperation with AEGIR-Marine is a part of this. Hydrex has more than 35 years of experience with repair and maintenance operations in the shipping and offshore industry. AEGIR-Marine has over 20 years of experience with stern tube seal and propeller repairs in its ranks. It was only a matter of time before the two companies found each other and started combining their experience and skills. Singapore. AEGIR started as a manufacturer-independent service company for stern tube seals and this is still the heart of the organization in 2011. Although AEGIR has had many developments and growth in a relative short period, one thing did not change: their approach and customer focus, which is similar to the Hydrex way of thinking. In 2005 we came in contact with Hydrex Senior Project Manager Ren Huybregts, recalls Ruud Muis. He invited us for a meeting at the Hydrex headquarters. Hydrex was at that point developing new ways of repairing stern tube seals underwater to broaden the services offered to their customers and had already carried out a few jobs successfully. Hydrexs flexible mobdock technology in combination with our brand-independence immediately turned out to be a perfect match. Together we could offer repairs for all types of seals, whether in drydock, on a trimmed vessel or underwater. Ruud says. In June 2006 a cooperation agreement was signed at the Poseidonia Exhibition in Greece. Since then the relationship has remained a successful one for both parties, continues Ruud. We all know each other personally, from the divers up to the managers. We can

A propeller blade after preventive cropping to make it less prone to damage from ice impact.

the owner wanted to find a way to prevent this from occurring on others of his container vessels. When the 2010-2011 winter promised to be equally harsh, he wanted to give the blades extra strength and make them less susceptible to damage from ice or other debris. This was done by modifying the blades to a very specific design that made them less prone to damage while keeping the performance of the propeller as close to optimum as possible. The operation was performed in close communication with both AEGIR-Marine Propulsion and the manufacturer of the propellers.

AEGIR-Marine

founder Ruud Muis.

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We were at that moment already offering the same service, but underwater. We therefore immediately saw the possibilities. Not only for the cropping of propeller blades, but also for the straightening of bent blades. Our knowledge of this subject has been vastly increased by working together with them. This enabled us to develop new techniques and equipment to carry out bigger operations and repair more comprehensive damage.
Hydrex Shiprepair Manager Martin Pauwels.

information and drawings, says Martin Pauwels. All information is then sent to AEGIR. They tell us if there is any specific problem or aspect we need to take into account for that specific job. Then we generate a quote which we send to the customer. An AEGIR service engineer is always present during an operation, not only to assist our divers, but also to prepare the seals and supervise their bonding. After the job has been coordinated with the people in the engine room, the Hydrex team leader and the AEGIR representative go on board together at the start of the job to discuss the scope of the operation with the crew members of the vessel. AEGIR also performs the final tests and signs off on their part of the operation. A propeller modification operation follows a slightly different route, says Martin Visser. Ideally we receive the information about the damage up front and then make a repair proposal that will bring the performance back as close to optimum as possible. Our role during the actual operation is purely a supportive one, to assist the divers whenever needed. After the job is completed we write a report. This is supplied as an addition to the Hydrex report. This is confirmed by Martin

therefore openly discuss operations, strategies and the future of our cooperation. We also pass on jobs to each other; for instance if no diving work is involved or if a customer needs another service than the one we offer. Hydrex Shiprepair Manager, Martin Pauwels remembers that AEGIRMarine already had a very comprehensive knowledge of seals and liners. This complemented our skills and knowledge well, not only from the point of view of the customers, but also internally to give all our team members a good understanding of what exactly a seal assembly entails, Martin says. There is a very good synergy between the two companies.

Martin Visser has had a personal relationship with Hydrex from the beginning of the nineties, independently from AEGIR-Marine, when he gave courses to several Hydrex team member to teach them how to replace face type seals underwater. This made it very easy for both parties to start working together on propeller modification operations after AMPS had been founded. As part of the AMPS team, Martin Visser supervises supporting services of the entire drive system of a ship, starting at the gearbox and including propeller blade modifications. AMPS perform both maintenance and repair work, he says. We can make all hydrodynamic calculations desired by the classification society or the customer. Like AEGIR-Marine, we are not restricted

Calculating the best cropping line makes it possible for the customer to know in advance what the result of the operation will be. He can then make an informed decision.
Our cooperation has only increased over the years. Having an AEGIR engineer on a job is an added value. At the beginning of 2009 AEGIR founded AEGIR-Marine Propulsion Services (AMPS) in partnership with DeViss Marine (lead by propulsion specialist Martin Visser) and started offering an extra service to its customers, Martin Pauwels tells us. They hired specialized people with a lot of experience. to certain brands, but we do have a specialization in LIPS/Wrtsil products.

What happens after an enquiry comes in?

If we, for instance, get an enquiry from a customer who has a ship with a stern tube seal problem, we ask them for all possible information; location, type of ship, type of seal, technical

AEGIR-Marine Propulsion Services propeller specialist Martin Visser.

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Pauwels. AMPS has the knowledge and computer programs to make a performance prediction and/or calculation after a planned cropping. This allows them to find the best cutting line which in turn makes it possible for the customer to know in advance what the result of the operation will be. He can then make an informed decision. To do these calculations AMPS needs the exact measurements of the damage. These are taken by the Hydrex diver/technician team during a detailed inspection and used by AMPS to make the required calculations.

continues Martin Visser. After some years of service an engine sometimes loses some of its performance. By calculating the possibilities of a propeller optimization we can restore the performance.

Trained and certified diver/ technicians

On a regular basis our divers are given a course at the AEGIR headquarters or our headquarters, says Martin Pauwels. With the aid of a dummy, the divers learn to bond the seal, but also what to do when opening up an assembly. They learn to look
Hydrex technician cropping a propeller blade to bring the propellers performance back as close as possible to its optimum condition.

In the end the customer is the real winner of this successful cooperation. Together Hydrex and AEGIR-Marine can offer a full package: work on all type of seals or propellers can be carried out in dock, on a trimmed vessel or underwater.
Martin Visser explains that during a propeller straightening operation, the blade is also restored to as close to its original form as possible. To be able to do this the Hydrex team has to find the cause of the bend. No calculations are necessary, but experience is essential in doing this and AMPS can support the team in this respect. Propeller optimization is sometimes also done to restore the performance even if no real damage has occurred, for damage on the liner, pieces that are broken off and other problems. Propeller repair training on the other hand is given on the job, but an inhouse training course for propeller operations is being established as we speak to give divers a good reality of what they can expect to encounter during an operation. Ruud Muis confirms this. Hydrex delivers the divers, equipment and the mobdock, and AEGIR helps ensure success and complete satisfaction for the custo-

mer. To be able to do this, all Hydrex team members are trained and certified by AEGIR. This training certificate is renewed every year.

Conclusion
In the end the customer is the real winner of this successful cooperation. Together Hydrex and AEGIR-Marine can offer a full package: work on all type of seals or propellers can be carried out in dock, on a trimmed vessel or underwater. This is a unique service in the shipping business. Both companies have expanded greatly over the last couple of years and are still growing. We keep on searching for ways to improve our relationship and the services we offer, in order to keep us standing out from the rest, concludes Ruud Muis. Despite the fact that we remain two separate companies we have established a very direct and open communication and cooperation. By offering an added value to our customers, we make sure that we are more than just the sum of the two companies separate services. Together we keep on looking for ways to make the offered service even better.

Training course given at the Hydrex headquarters by an AEGIR-Marine engineer in 2006 in the presence of Hydrex Shiprepair Manager Martin Pauwels.

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