Maximising productivity, efficiency, and safety in your shipboard repair operations By Chris Teoh Global Product Marketing Manager – Welding and Tools Solution
Industry 4.0 The Fourth Industrial Revolution, more commonly referred to as Industry 4.0, is the automation of traditional practices using modern innovative technology. Over the years, digitally aware industries such as automotive, aerospace and manufacturing, have been leading the drive towards Industry 4.0. Companies such as Bosch and Ford actively leverage the benefits of innovation to increase productivity, reduce costs, and improve efficiency.
“Industry 4.0 technologies were already transforming manufacturers’ operations before the pandemic. Now adoption is diverging between technology haves and have-nots.”� - McKinsey
Saying that the pandemic has disrupted the global shipping industry is an understatement. Let’s do a quick recap of how the sector is currently gripped by arguably the most turbulent period in its recent history.
What does industry 4.0 mean for the maritime industry? Some players have been embracing the trend, with the advent of increasingly connected ports and autonomous ships.5 However, the industry in general is slow to adopt this, and much more is needed. There is also a need to understand that automation does not only apply to ports. Pivoting to better solutions will enable ship operators to enjoy the benefits of increased efficiency, improved productivity, reducing the risk of supply chain disruption and to personnel.
When COVID-19 first hit, it brought the industry to a virtual standstill – shipping demand dropped, vessels were delayed, port entry was restricted, and more. According to the University of Oxford, the pandemic caused a 10% collapse in maritime trade in the first eight months of 2020, creating losses of up to $412 billion.1 As of July 2021, around 500,000 seafarers are either stranded on ships or unable to get on board the vessels, due to travel restrictions imposed worldwide. There are only a few signs of the problem getting more manageable, which IMO has described as a humanitarian, safety, and economic crisis.2 At a time when the industry was, and is still, running out of vessels, containers and resources, ship owners can’t afford any further potential disruptions to their shipping schedules. They are under immense pressure to operate at high capacity and minimise time spent on ship repair and maintenance to avoid losing opportunities.
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The ability of shipping services to continue undisrupted to transport food, energy and medical supplies across the continents will play a critical role in overcoming this pandemic. Shipping companies will need to become agile and adaptable to this changing situation.”� - PwC
Leveraging on more efficient technology A key area where improvements can be made is in effective repair and maintenance. According to ResearchAndMarkets, the global ship repairing market is expected to grow from $30.16 billion in 2020 to $32.29 billion in 2021 at a compound annual growth rate (CAGR) of 7.1%.6 Why so? The shipping industry is actively exploring ways to be better prepared for an endemic world, one where the world is slowly opening up but yet has to be flexible enough to adjust to unforeseen changes. Shipboard welding and cutting are critical aspects of repair and maintenance programmes to ensure vessels are operational. Today’s ship operators can choose from a wide range of welding and cutting equipment, and making the right selection is crucial in improving operations on board.
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Industry 4.0 The Fourth Industrial Revolution, more commonly referred to as Industry 4.0, is the automation of traditional practices using modern innovative technology. Over the years, digitally aware industries such as automotive, aerospace and manufacturing, have been leading the drive towards Industry 4.0. Companies such as Bosch and Ford actively leverage the benefits of innovation to increase productivity, reduce costs, and improve efficiency.
“Industry 4.0 technologies were already transforming manufacturers’ operations before the pandemic. Now adoption is diverging between technology haves and have-nots.”� - McKinsey
Saying that the pandemic has disrupted the global shipping industry is an understatement. Let’s do a quick recap of how the sector is currently gripped by arguably the most turbulent period in its recent history.
What does industry 4.0 mean for the maritime industry? Some players have been embracing the trend, with the advent of increasingly connected ports and autonomous ships.5 However, the industry in general is slow to adopt this, and much more is needed. There is also a need to understand that automation does not only apply to ports. Pivoting to better solutions will enable ship operators to enjoy the benefits of increased efficiency, improved productivity, reducing the risk of supply chain disruption and to personnel.
When COVID-19 first hit, it brought the industry to a virtual standstill – shipping demand dropped, vessels were delayed, port entry was restricted, and more. According to the University of Oxford, the pandemic caused a 10% collapse in maritime trade in the first eight months of 2020, creating losses of up to $412 billion.1 As of July 2021, around 500,000 seafarers are either stranded on ships or unable to get on board the vessels, due to travel restrictions imposed worldwide. There are only a few signs of the problem getting more manageable, which IMO has described as a humanitarian, safety, and economic crisis.2 At a time when the industry was, and is still, running out of vessels, containers and resources, ship owners can’t afford any further potential disruptions to their shipping schedules. They are under immense pressure to operate at high capacity and minimise time spent on ship repair and maintenance to avoid losing opportunities.
2
The ability of shipping services to continue undisrupted to transport food, energy and medical supplies across the continents will play a critical role in overcoming this pandemic. Shipping companies will need to become agile and adaptable to this changing situation.”� - PwC
Leveraging on more efficient technology A key area where improvements can be made is in effective repair and maintenance. According to ResearchAndMarkets, the global ship repairing market is expected to grow from $30.16 billion in 2020 to $32.29 billion in 2021 at a compound annual growth rate (CAGR) of 7.1%.6 Why so? The shipping industry is actively exploring ways to be better prepared for an endemic world, one where the world is slowly opening up but yet has to be flexible enough to adjust to unforeseen changes. Shipboard welding and cutting are critical aspects of repair and maintenance programmes to ensure vessels are operational. Today’s ship operators can choose from a wide range of welding and cutting equipment, and making the right selection is crucial in improving operations on board.
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Which welding and cutting solutions are best for you?
Wire welding and plasma cutting – the ideal ways forward In many parts of the world, a growing number of ship operators are turning to wire welding and plasma cutting as safer and more effective solutions to increase productivity, with a lower total cost of ownership compared to other methods. While neither process is new, their popularity has increased in recent years. Wire welding currently represents over 45% of the total global welding consumables sold in the welding industry over the past decade.
Improved safety and more user friendly Wire welding and plasma cutting are faster, more user-friendly and efficient than conventional processes. A wire welding set-up would consist of a power source, a wire welding torch, welding consumables (typically 5kg or 15kg wire spool) and a gas supply if gas shielded wire welding is required. This method is easy to set up and safe to use, and much easier to learn compared to stick electrode welding, which needs the ability to strike and maintain an arc.
There is a range of welding options currently available, including oxy-acetylene, stick electrode, TIG and wire welding. For shipboard cutting, the two main options are oxy-acetylene and plasma cutting. Where time isn’t critical and a high standard of finish isn’t essential, stick electrode welding is the most common welding method. Likewise, where time savings and quality aren’t vital factors in steel cutting operations, the traditional process of oxy-acetylene gas cutting still predominates.
Wire welding can be up to 30% faster than stick electrode welding. The suggested travel speed for stick electrode welding is 75 to 150 mm per minute. Wire welding travel speeds are typically 150 to 250 mm per minute.8 As for plasma cutting, its versatility and high heat source mean it can be used to cut any electrically conductive material such as carbon steel, stainless steel, aluminium, cast iron, duplex, super duplex, Inconel, copper, and titanium. This is a significant benefit for repair works where materials like aluminium or stainless steel are used on sections like vessel process piping and tanks, food preparation galley, railings and gratings.
However, it can be difficult and costly to hire an experienced welder, especially when we are experiencing a significant shortage of skilled welders. In addition to the fact that an average rate to hire a professional is now at $15 to $20 per hour7, with limits on the number of crew members on board, finding someone with the skills to perform stick electrode welding or oxy-acetylene cutting accurately and safely can be a real challenge.
Increased productivity
Stick electrode welding requires higher consumption of consumables over deposited weld metal due to its lower efficiency. This method is restricted by the length of the electrodes, which are limited to 450mm in length and are disposed of when they become reduced to an electrode stub. The process creates wastage: about 10% of the electrode stub’s weight ends up as scrap or is unused (a rule of thumb is 1.5kg of electrode mass for every 1kg of weld metal).
Stick electrode welding allows only about 12 minutes of welding for every hour an arc is generated. By comparison, wire welding can give up to 30 minutes of welding time per hour of arc generation.
In terms of load, conventional welding and cutting equipment can be heavy to lift and move. The bulkiness poses a problem in the maintenance process, especially when it comes to areas that are difficult to access. While traditional welding and cutting processes are still commonplace, it’s time for ship operators to consider other methods that are more versatile and portable, ones that will maximise efficiency, productivity, and safety – which are especially important in this new world we operate in.
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By using wire spools, wire welding allows for continuous welding. This means it can deliver a higher duty cycle (longer arc-on time) and faster travel speeds. In contrast, stick electrode welding requires stops at short intervals to de-slag, change electrodes and restart after each 200 to 300mm of welding.
Meanwhile, plasma cutting uses compressed air and electricity readily available on board to deliver a ‘cleaner’ cut compared to oxy-acetylene cutting. This process results in more accurate, versatile, and higher cutting speeds and productivity for steel thicknesses up to 15mm.
Lower total cost of ownership (TCO) While the initial outlay for wire welding and plasma cutting equipment may be higher than conventional standard welding tools, their greater speed, efficiency, performance, productivity and reduced waste mean lower overall project costs. In addition, as you would only use what you need for wire welding, the likelihood of wastage is minimised significantly, bringing a lower TCO for the project.
5
Which welding and cutting solutions are best for you?
Wire welding and plasma cutting – the ideal ways forward In many parts of the world, a growing number of ship operators are turning to wire welding and plasma cutting as safer and more effective solutions to increase productivity, with a lower total cost of ownership compared to other methods. While neither process is new, their popularity has increased in recent years. Wire welding currently represents over 45% of the total global welding consumables sold in the welding industry over the past decade.
Improved safety and more user friendly Wire welding and plasma cutting are faster, more user-friendly and efficient than conventional processes. A wire welding set-up would consist of a power source, a wire welding torch, welding consumables (typically 5kg or 15kg wire spool) and a gas supply if gas shielded wire welding is required. This method is easy to set up and safe to use, and much easier to learn compared to stick electrode welding, which needs the ability to strike and maintain an arc.
There is a range of welding options currently available, including oxy-acetylene, stick electrode, TIG and wire welding. For shipboard cutting, the two main options are oxy-acetylene and plasma cutting. Where time isn’t critical and a high standard of finish isn’t essential, stick electrode welding is the most common welding method. Likewise, where time savings and quality aren’t vital factors in steel cutting operations, the traditional process of oxy-acetylene gas cutting still predominates.
Wire welding can be up to 30% faster than stick electrode welding. The suggested travel speed for stick electrode welding is 75 to 150 mm per minute. Wire welding travel speeds are typically 150 to 250 mm per minute.8 As for plasma cutting, its versatility and high heat source mean it can be used to cut any electrically conductive material such as carbon steel, stainless steel, aluminium, cast iron, duplex, super duplex, Inconel, copper, and titanium. This is a significant benefit for repair works where materials like aluminium or stainless steel are used on sections like vessel process piping and tanks, food preparation galley, railings and gratings.
However, it can be difficult and costly to hire an experienced welder, especially when we are experiencing a significant shortage of skilled welders. In addition to the fact that an average rate to hire a professional is now at $15 to $20 per hour7, with limits on the number of crew members on board, finding someone with the skills to perform stick electrode welding or oxy-acetylene cutting accurately and safely can be a real challenge.
Increased productivity
Stick electrode welding requires higher consumption of consumables over deposited weld metal due to its lower efficiency. This method is restricted by the length of the electrodes, which are limited to 450mm in length and are disposed of when they become reduced to an electrode stub. The process creates wastage: about 10% of the electrode stub’s weight ends up as scrap or is unused (a rule of thumb is 1.5kg of electrode mass for every 1kg of weld metal).
Stick electrode welding allows only about 12 minutes of welding for every hour an arc is generated. By comparison, wire welding can give up to 30 minutes of welding time per hour of arc generation.
In terms of load, conventional welding and cutting equipment can be heavy to lift and move. The bulkiness poses a problem in the maintenance process, especially when it comes to areas that are difficult to access. While traditional welding and cutting processes are still commonplace, it’s time for ship operators to consider other methods that are more versatile and portable, ones that will maximise efficiency, productivity, and safety – which are especially important in this new world we operate in.
4
By using wire spools, wire welding allows for continuous welding. This means it can deliver a higher duty cycle (longer arc-on time) and faster travel speeds. In contrast, stick electrode welding requires stops at short intervals to de-slag, change electrodes and restart after each 200 to 300mm of welding.
Meanwhile, plasma cutting uses compressed air and electricity readily available on board to deliver a ‘cleaner’ cut compared to oxy-acetylene cutting. This process results in more accurate, versatile, and higher cutting speeds and productivity for steel thicknesses up to 15mm.
Lower total cost of ownership (TCO) While the initial outlay for wire welding and plasma cutting equipment may be higher than conventional standard welding tools, their greater speed, efficiency, performance, productivity and reduced waste mean lower overall project costs. In addition, as you would only use what you need for wire welding, the likelihood of wastage is minimised significantly, bringing a lower TCO for the project.
5
Unitor new generation of welding and cutting equipment At Wilhelmsen, our Unitor New Generation Welding and Cutting Equipment enables ship operators to achieve all the benefits of wire welding and plasma cutting while complementing existing tools available on board, providing greater flexibility and more options. The UWW-301 TP is a 3-in-1 multi-purpose welding machine that performs wire welding, stick electrode welding, and TIG DC Lift Arc welding, enabling solid welding results in any given situation. The UPC-NEO NG is a high-performance plasma cutter with an excellent weight-tocutting capability ratio for various steel such as carbon steel, stainless steel, aluminium, or any electrically conductive metal. These machines are lightweight, portable, compact, and easy to set up, which makes them the perfect and most suitable tool to meet the ever-challenging demands and complexities of today’s shipboard welding and cutting works.
Time for a change? The benefits of wire welding and plasma cutting can help ship operators fully meet the challenging and changing demands of today’s fast-moving world. As mentioned in the article, wire welding and plasma cutting can enhance productivity, efficiency and safety, and deliver a lower total cost of ownership for projects. Both have been proactively used in leading industries such as automotive, shipyards, and fabrication for several years. For example, they are even revolutionising opportunities for industry development when combined with next-generation robotics and automation. There is no reason why the shipping industry can’t make good use of these benefits. It is time for us to work towards better maintenance and repair programmes.
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Unitor new generation of welding and cutting equipment At Wilhelmsen, our Unitor New Generation Welding and Cutting Equipment enables ship operators to achieve all the benefits of wire welding and plasma cutting while complementing existing tools available on board, providing greater flexibility and more options. The UWW-301 TP is a 3-in-1 multi-purpose welding machine that performs wire welding, stick electrode welding, and TIG DC Lift Arc welding, enabling solid welding results in any given situation. The UPC-NEO NG is a high-performance plasma cutter with an excellent weight-tocutting capability ratio for various steel such as carbon steel, stainless steel, aluminium, or any electrically conductive metal. These machines are lightweight, portable, compact, and easy to set up, which makes them the perfect and most suitable tool to meet the ever-challenging demands and complexities of today’s shipboard welding and cutting works.
Time for a change? The benefits of wire welding and plasma cutting can help ship operators fully meet the challenging and changing demands of today’s fast-moving world. As mentioned in the article, wire welding and plasma cutting can enhance productivity, efficiency and safety, and deliver a lower total cost of ownership for projects. Both have been proactively used in leading industries such as automotive, shipyards, and fabrication for several years. For example, they are even revolutionising opportunities for industry development when combined with next-generation robotics and automation. There is no reason why the shipping industry can’t make good use of these benefits. It is time for us to work towards better maintenance and repair programmes.
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References: 1 https://www.ox.ac.uk/news/2021-04-15-tracking-economic-impacts-covid-19-one-ship-time 2 https://www.imo.org/en/MediaCentre/HotTopics/Pages/FAQ-on-crew-changes-and-repatriation-of-seafarers.aspx 3 https://www.pwc.com/gr/en/industries/shipping-covid-19.html 4 https://www.mckinsey.com/business-functions/operations/our-insights/industry-40-reimagining-manufacturing-operations-after-covid-19 5 increasingly connected ports and the emergence of autonomous ships 6 https://www.researchandmarkets.com/reports/5323258/ship-repairing-global-market-report-2021-covid#src-pos-1 7 https://www.ziprecruiter.com/Salaries/Welder-Salary-per-Hour 8 http://www.haynesintl.com/alloys/fabrication-brochure/welding-and-joining/gas-metal-arc-welding-(gmaw-mig-)