Halliday Engineering were recently engaged to carry out repairs to a Cargo ship operating on Bass Straight

The ship is the primary transporter of cargo between Melbourne and Burnie (Tasmania). It was the largest cargo ship registered in Australia when it was launched in 2019. The vessel is 211m in length (28m beam), with a capacity of 700 TEU and 3000 lane-metres. It is operated by a major Multinational Freight Forwarder.

The job involved replacing an existing a 500mm Nb overboard discharge pipe. The vessels managers had previously determined, via ultrasonic thickness inspections, that the pipe required replacement. The defective pipe penetrated the vessel’s hull below the water line, meaning that the pipe could not simply be cropped and replaced, as this would result in an ingress of water and catastrophic failure. Adding to the complexity of it all, all work had to be performed without disrupting the vessels operational demands.

Our job involved attending Melbourne, viewing the ship and formulating an acceptable repair methodology with Lloyds and the vessel managers. We then attended Burnie to commence works. The first critical step was to weld a cofferdam onto the external surface of the hull (over the pipe penetration). This was conducted by SDS divers from Subsea global Solutions and allowed our fabricators to crop the existing pipe without the ingress of water.

Our fabricators then went about jigging the removed pipe and fabricating the replacement pipe. The jig ensured the manufactured pipe would be an exact replica of that removed. Once fabricated, all welds were checked via NDT and the pipe was coated in appropriate wear resistant coating. The pipe was then offered up to the installation point for fit-up checks prior to welding. Final welding and NDT checks were then conducted prior to removing the installed cofferdam.

The project was conducted safely and without delay to the vessel. Another happy customer!

The hardest part of the job was working to the timeframes that the ship was moored. We had to go on board, set up and then get back off and leave it in a safe condition, so it could sail again. We had to get a lot done in set periods of time.

Cameron Martin (Tai) – Project Supervisor

KEY ASPECTS OF THE JOB

Important delivery vessel

The vessel delivers critical cargo to Tasmania. It only stops while it is being loaded/unloaded. It was imperative that the vessel maintained its tight schedules or it could potentially miss booked port windows.

Fabrication

CLASS qualified welders, procedures and the equipment to weld Structural Hull Plate. All welds inspected by independent NATA accredited Non-Destructive Testing Laboratory and in accordance with Lloyds Requirements.

Safety

The work onboard the vessel was high risk, involving hotwork, suspended loads and possible engulfment. Risk mitigation and appropriate controls ensured the job was performed safely and without incident.

Covid safety

Our travelling team were also required to meet Strict COVID safety requirements, remaining in isolation unless working on the vessel.

Cameron Martin (Tai)

Project Supervisor overseeing the project planning, fabrication and install. Tai had the foresight and project management skillsets to plan well in advance ensuring our team were ready to execute. This resulted in quicker project delivery times and cost-savings that were handed onto the client.

Working Remotely

One of our Halliday Work Containers was loaded in Sydney and freighted to the vessel. Ensuring we had everything we needed to do the job and could set up a mobile workshop on location. We were primed and ready to start work as soon as the vessel was tied up.

Everyone was a specialist at their job and we made a great team to get the job done.

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