Underwater Repair: Rudder Fixation of M/V Kamari

This report provides a comprehensive analysis of the rudder fixation project for the MV Kamari, conducted from a maritime project management perspective. Executed between December 18 and 22, 2024, this operation was uniquely performed at sea rather than in a shipyard, highlighting the team’s adaptability, technical expertise, and efficient resource management under challenging conditions.

1. Project Overview

The primary goal of the project was to stabilize the rudder of the MV Kamari at a zero-degree position, eliminating vibrations and hammering against the hull to ensure the vessel’s safe towing from Brazil to Spain. The rudder had lost its upper stock (axis), causing severe instability due to hydrodynamic forces, which required immediate technical intervention.

The operation was executed by Seachios Marine Services and Globo Underwater Services, with engineering consultancy provided by TowService BV. Onboard supervision was conducted by Mr. Dionysios Spathis, representing A.M Nomikos and Kamari Shipping Ltd, the vessel owners. Unlike traditional repairs in a controlled shipyard environment, this project was carried out at sea, introducing complexities such as unpredictable weather, limited resource access, and the need for portable equipment. Despite these challenges, the project was completed in just five days, showcasing significant efficiency and cost savings.

2. Project Management Perspective

a. Planning and Preparation

• Detailed Planning: The operation demanded precise planning due to its at-sea execution. Materials such as pad-eyes, chains, turnbuckles, and underwater welding electrodes were carefully selected for their suitability in a marine environment and portability to the vessel.

• Stakeholder Coordination: Success relied on seamless collaboration among multiple parties, including Seachios Marine Services, Globo Underwater Services, TowService BV, Kamari Shipping Ltd, and the onboard superintendent. Effective communication ensured alignment across all teams.

• Aggressive Timeline: Spanning from December 18 to 22, 2024, the five-day schedule reflects rapid mobilization and execution, even with initial setbacks such as a motor failure during material transport on the first day.

b. Execution and Adaptation

• At-Sea Challenges: The maritime environment introduced variables like waves, currents, and limited underwater visibility. The team adapted by employing underwater welding, chain hoists, and portable equipment to align and secure the rudder.

• Technical Interventions: During execution, the rudder’s hammering motion caused a sling to fail, prompting immediate adjustments. The team installed:

  • Pipe 1: 32 cm diameter, 17 cm x 22 cm.

  • Pipe 2: 32 cm diameter, 20.5 cm x 22 cm (aft support for Pipe 1).

  • Additional reinforcements included wedges and steel bars to eliminate movement.

• Specialized Skills: Highly skilled divers and welders, guided by TowService BV’s expertise, performed precise tasks in adverse conditions, ensuring the operation’s success.

c. Risk Management

• High-Risk Environment: Working at sea heightened risks such as equipment failure, diver safety, and potential vessel damage. The sling failure incident underscored these challenges.

• Mitigation Measures: Multiple reinforcement layers—custom pipes, wedges, steel bars, and additional cables—ensured rudder stability. Equipment was chosen with high safety factors:

  • Shackles: 6:1 safety factor.

  • Turnbuckles: 5:1 safety factor.

• Safety Protocols: Divers used complete gear, and insulated welding cables were employed, prioritizing safety throughout the operation.

d. Quality Control and Outcome

• Stabilization Achieved: The rudder was immobilized at zero degrees, eliminating vibrations and hammering. The "M/V Kamari Rudder Plan" diagram details the final configuration, including pad-eyes, turnbuckles, chains, and welded reinforcements.

• Innovative Solutions: Custom-fabricated pipes and wedges demonstrated the team’s ability to innovate under pressure, ensuring long-term stability for towing.

• Towing Readiness: The vessel was declared fit for safe towing to Spain, meeting the project’s primary objective within the tight timeline.

3. Impact of Execution at Sea

Performing the project at sea, rather than in a shipyard, had profound implications:

• Adaptability: The team adjusted methods and equipment to an uncontrolled environment, managing sea conditions and limited resources effectively.

• Logistics: Transporting materials to the vessel at sea, despite delays like the motor failure, required exceptional coordination.

• Efficiency: Avoiding shipyard transit saved time and costs, showcasing the value of on-site solutions.

• Expertise: Success depended on skilled personnel capable of complex repairs in challenging conditions, emphasizing the need for specialized knowledge.

4. Conclusion

The rudder fixation project for the MV Kamari exemplifies excellence in maritime project management. Completed at sea in five days, it demonstrates meticulous planning, effective coordination, robust risk management, and adaptability to adverse conditions. The outcome—a stabilized rudder, eliminated vibrations, and a tow-ready vessel—reflects the team’s technical prowess and innovative approach.

This operation proves that complex repairs can be successfully executed outside shipyards with proper planning and skilled personnel, offering significant time and cost benefits when risks are well-managed. It sets a precedent for future at-sea maritime operations, highlighting the industry’s capacity to tackle logistical and technical challenges in demanding environments.

Enhanced Chart: Project Timeline and Equipment Utilization

Below is an incremented chart detailing the project timeline and equipment utilization for the MV Kamari rudder fixation. This stacked bar chart provides a day-by-day breakdown from December 18 to 22, 2024, with additional annotations and metrics for a more comprehensive view of progress and resource allocation.

Chart Description

• X-Axis: Project days (December 18-22, 2024).

• Y-Axis: Utilization (0 to 1, where 1 represents full activity dedication to a specific equipment type or equal division among multiple types).

• Stacked Bars: Each bar is segmented by color, representing different equipment types used daily.

• Annotations: Key events (e.g., motor failure, sling failure) are noted to contextualize progress.

• Legend: Associates colors with equipment types, positioned at the bottom.

Equipment Types and Colors

• Fixation (Blue, #1f77b4): Pad-eyes, chains, turnbuckles.

• Lifting (Green, #2ca02c): Chain hoists.

• Welding (Red, #d62728): Underwater welding electrodes and equipment.

• Reinforcement (Yellow, #ff7f0e): Custom pipes, steel bars, wedges.

• Safety (Purple, #9467bd): Steel cables, clamps, safety gear.

Daily Activity Breakdown

• December 18: Material Collection and Transport (100% Fixation). Note: Motor failure delayed initial progress.

• December 19: Onboard Preparations and Chain Hoist Installation (50% Fixation, 50% Lifting).

• December 20: Underwater Welding and Rudder Alignment (50% Welding, 50% Lifting). Note: Sling failure required adjustments.

• December 21: Reinforcement Welding (50% Welding, 50% Reinforcement).

• December 22: Final Welding and Cable Securing (50% Safety, 50% Fixation).