On-board maintenance solutions for the marine industry

Surface preparation

Corrosion protection is vital in the corrosive seawater environment. Many techniques are used to prepare a surface for effective corrosion protection, with sandblasting being the most common. Yet this technique suffers from a major disadvantage: the vast quantity of dust produced. Apart from the health and safety issues of clouds of dust – not only for the operators but for people in the immediate vicinity – the cost and disposal of the abrasive also has to be taken into account. Moreover, conventional sandblasting can not be used on an ATEX vessel due to the risk of explosion. One alternative technology is ultra-high pressure (UHP) water jetting. But this is highly dangerous for the operator as it throws debris over a large area. And it does not lead to a satisfactory surface preparation quality. 

To counter these issues, Graco has developed a revolutionary alternative: vapor abrasive blasting with EcoQuip™. The technology involves adding water simultaneously with the abrasive media in a pressure pot. The abrasive becomes suspended in water, and the mixture is then projected at high velocity by a forceful flow of compressed air. EcoQuip provides a performance equivalent to sandblasting but with 92% less dust, thus minimizing the need for PPE, tenting and containment, and decreasing environmental impact. It uses up to 75% less blast media and far less water than wet blasting, and creates little run-off, thus there is no large slurry mess to clean-up and dispose. It’s effective in rain and high humidity, and efficiently removes coatings without damaging the sub-surface.

EcoQuip cleans vessels without damaging the protective gel-coating, and leaves a perfect 80-grit finish, which is the ideal anchor pattern for paint adhesion. In just minutes, it exposes welds for inspection and maintenance of steel and aluminium hulls and removes old varnish. The system even works under water and cleans surfaces with years of growth and barnacle build-up in a matter of minutes. The technology allows props, rudders and trim tabs to be restored to their original integrity without being removed from the vessel. The bottom line is that EcoQuip reduces project costs while increasing the speed, efficiency and productivity of blasting.

Pumping

A multitude of machines and operations on-board a vessel depend on the efficient running of a pump. Take wastewater, for example. Ships produce two types of wastewater: black or grey. Black wastewater contains sewage or water used in medical procedures; grey wastewater consists of run-off from showers, sinks and laundries. The discharge of both black and grey wastewater at sea is prohibited. Pumps play an indispensable role in moving wastewater through the ship and into various treatment and storage tanks prior to its eventual disposal.

Another key role for pumps is to ensure efficient and accurate fluid or media metering and dosing. Examples include accurate dosing for efficient boiler operation, or for adding chemicals to cooling water systems to protect against corrosion. Damage to vital machinery can result from under- or over-dosing, so the right choice of metering pump is essential.

Given the importance of pumps in a variety of on-board operations, pump failures can therefore be disastrous, and a frustrating waste of time, energy and money. So it comes as no surprise to find that Graco has devoted considerable resources to attempt to eliminate them. In addition, Graco constantly seeks to improve the energy efficiency of pumps and create a quieter working environment for operators and nearby employees.

Two results of Graco’s developments in this area are the Husky™ 1050 and 2150 air-operated double-diaphragm pumps. Designed for high efficiency and durability, these two pumps deliver material from 80 to 569 lpm. Their diaphragm has been tested and found to last up to five times longer than others in its class. The pumps feature a stall-free, low pulsation air valve which provides a smooth and rapid changeover. In the marine industry these pumps are proving essential for pumping oil, sludge or highly abrasive chemicals. They can be fully submerged, which makes them ideal to pump out slurries from the bottom of tanks or bilges.

Of course, there are times when a pump is needed on a vessel in locations where no air is available – or will take a lot of time and logistics to get an air supply up and running. This is where Graco’s Husky™ 1050e or 2150e prove invaluable. These electric double-diaphragm pumps stand out by being the only electric diaphragm pumps on the market that will stall under pressure, to prevent pump failures from clogged lines or closed valves. Moreover, their energy- efficient electric drive reduces energy consumption by up to five times compared to traditional air-operated diaphragm pumps. They can also be set to reduce pulsations, negating the need for a pulsation dampener – which contributes to their low noise levels.

Lubrication

Machinery used on board vessels face a grueling combination of challenges. These include high mechanical loads and vibration, temperature fluctuations, UV radiation, rain and strong winds. The continuous battle against the effects of salt water is a particular problem for marine machinery. Failure of winches or cranes, or of moving parts in gearboxes, propeller shafts or steering gears can result in significant unplanned downtime, delays, lost productivity and high repair bills.

Effective lubrication is the key, but this means getting the balance exactly right between under- and over-lubrication. This is why automatic lubrication systems are vital, because they provide smaller amounts of lubricant at more frequent intervals, avoiding both under- and over-lubrication. Automatic lubrication results in extended equipment life, reduced wear and smaller maintenance bills. It can even be set up with features that detect a blocked or broken line, and then alert the operator.

One example of automatic lubrication equipment from Graco is the Trabon LubeMaster, a rugged, reliable pump to lubricate all types of marine machinery. It can be driven by an electric motor or a rotating or oscillating machine motion, and the output is readily adjustable. The LubeMaster is designed to pump grease or oil efficiently at a wide range of pump cycle rates and pressures. Anti-friction drive bearings and simplified design improve pump operation and reliability. Its broad output range and interchangeability of drive and mounting selections make it suitable for a wide range of marine applications. Optional high-pressure and low-level switches are available to provide protection against excessive system pressure and low reservoir lubricant levels.

Of course, not every lubrication application needs an automatic approach. For over 60 years, Graco Fire-Ball® pumps and packages have been a mainstay in the on-board lubrication marketplace on account of their durability and long life. Designed for the toughest applications, the Fire-Ball brand repeatedly outperforms and outlasts the competition. Fewer moving parts in the air motor assembly means less downtime and low repair cost. In-built flexibility is a key feature of the Fire-Ball®: you can choose a pump to perfectly match your low-, medium- or high-volume marine lubrication applications.

If you’re looking for a lubrication system to easily move around a vessel on a cart, then the Graco LD Series Grease Pump Cart Mount Package with Reel will meet your requirements perfectly. These affordable and full-featured pumps are designed for lower-volume (up to 3175 kg/year) applications. LD pumps are fine-tuned for a compact, flexible and durable solution.

Another key Graco pump that is used in marine applications throughout the world is the G3. Thanks to its flexible design, it works with injector-based and series progressive systems. This cost-effective pump offers a choice of three controllers, with multiple zone and feedback options. It includes one adjustable pump element as standard, plus room for two more. Multiple reservoir choices are also possible, to provide the ultimate in flexibility for a high value, custom fit for an automatic lubrication system. Graco’s exclusive Data Management System (DMS™) enables you to find out exactly how your lubrication system is performing. It tracks history, provides data protection, and enables data to be easily uploaded or downloaded using a simple USB flash drive. The Graco G3 has been consistently proved to extend machinery life, reduce operating costs and increase productivity.