Projects Executed
MAINTENANCE OF DIESEL ENGINES AND GENERATORS
PREVENTIVE MAINTENANCE AT CLIENT SITE
Dahra Global team as part of an on-going contract for a major oil & gas client has completed maintenance and corrective repairs on Emergency Diesel generators, Alternators and associated cooling fan motors.
A total of 15 nos. Engines with Generators are being monitored by our team under the preventive maintenance regime. The Containerised engines are of various makes, viz. MTU, Volvo, Wartsila, GMT & Deutz. We have undertaken routines for filter replacement, lube oil change & coolant replacement as part of the scope. The Alternator bearings are also greased as part of the routine. In particular, the cooling fans with motors are located outside the container and are exposed to severe weather conditions and mandate regular maintenance to ensure continuous operational availability. Our team has performed the above works with all necessary safety precautions and PTW requirements associated with hazardous gas plants viz, Working at height, Gas masks for exposure to chemicals, personnel PPE etc.
As part of the contract, our team also undertook emergency repairs of the fuel system via replacement of fuel feed pump and associated fuel hoses. This scope was completed successfully in the late night – early morning hours along with supply of spares.
INSTALLATION & COMMISSIONING OF WATER MAKER
The process of Installation & commissioning involves activities such as site survey, site preparation, verifications, tests, evaluation of functional requirements essential for the new plant for routine operation. Dahra Global team recently completed an installation and commissioning of Water Maker (HP SC440-4 RP TRONIC) onboard a vessel at Doha.
Scope of the Work entailed: –
- Site survey to identify the requirements of the client and to check the feasibility of incorporating these requirements
- Removal of old existing plant and undertake requisite modifications to the foundation & systems
- Identifying correct reliable equipment to fulfill client requirements according to site conditions
- Scheduling of activities for each stage of installation and commissioning
- Preparation of commissioning check list
- Training on operation and maintenance
The new equipment is fully automatic and needs fresh water during initial starting for few seconds and the ship system does not feed water to this plant directly. This problem was resolved by taking additional line from ships system with some modifications. Another teething issue that came up was that the vessel had a 230V control supply system and the OEM provided plant works on 110 V. This was overcome by installation of an OEM approved Transformer. Dahra Global technical team completed the installation and commissioning in time with customer satisfaction and also provided training on Operation & Maintenance with all relevant documentation.
SERVICES FOR ENGINE ROOM CONTROL, AUTOMATION SYSTEMS DEFECTS
Dahra Global Technologies undertook defect analysis and rectification services for Engine & Boiler controls, Switchboard earthing fault & HVAC controls onboard Bulk carrier vessel sailing under Flag of Marshall Islands at Mesaieed port. The turnaround call for the vessel was 24-hours only. Our team of automation engineers attended the call and aided in defect identification and subsequent rectification of following defects: –
- Alarm monitoring system for Engine Control System
- Boiler low-low level alarm
- Engine room & AC room ventilation fan control
- Main engine exhaust gas temp. & viscosity controller sensor feedback to ECR
Our engineers attended the defects and provided a detailed report on the nature of defect, defect remedial methodology & spares required. This report enabled the crew to source the correct spares and rectify above control defects. Our automation engineers are capable of correct fault diagnosis leading to expeditious defect rectification with their vast marine experience, enabling the vessel & sea farers to meet their operational roles.
OVERHAULING OF CRANE ONBOARD WOODEN DHOW
“Maintenance” keeps machinery up to date and in smooth running condition, irrespective of size. Efficient maintenance enhances life and ensures equipment performance at its optimal level with minimal costs. Dahra Global has a dedicated team for undertaking maintenance of critical equipment with / without OEM support. In the present scenario of COVID-19, wherein OEM support was unavailable, Dahra Global technical team could analyse the defect, provide innovative solution, provision spares and thereafter execute the job within 02 days including dismantling, overhauling, final pressure testing & commissioning for the Crane.
Scope of the Work entailed: –
- Rectification of defect regarding sluggish response during operation and leakages from control valves
- Flushing & Overhauling of complete hydraulic power pack system and control valves
- Supply of customised crane rope slings to enable extended lengths during operations
Post overhauling and installation, normal operation of the crane was restored. Dahra global team is confident of undertaking similar works for repairs, maintenance & overhauls of various cranes and their hydraulic systems for any client in Qatar.
of Yacht Crane
Maintenance and Load testing of Yacht Crane
Our service engineers recently carried out Annual Maintenance works of a 5Ton crane on a Yacht. The scope included replacement of wire rope, swivel block & complete maintenance of the crane hydraulic and control systems. Close coordination by the sales team resulted in expediting receipt of OEM spares from Europe despite COVID-19 lockdown. Post completion of maintenance, the crane was successfully load tested in the presence of Client. The task of Maintenance and Load testing was accomplished in a span of 06 hours enabling Client to meet the sailing commitment of the Yacht.
Support Services - Arleigh Burke Class Destroyer at Qatar
An US Navy Warship (Arleigh Burke-class destroyer) sought assistance for Installation of a new clutch assembly for their Gas Turbine Propulsion Plant. Our team of marine specialists executed the task entailing “shifting of the clutch assembly” from ashore to the “Engine room” of the ship (A precise lifting plan was prepared to avoid damage to sensitive communication antennas fitted on the Superstructure of the warship). Subsequently, we provided assistance and guidance to the vessel crew in installation of the unit on the Gas turbine. The complete task was successfully executed in a span of 10 hours. Additionally, our team overhauled six pressure relief valves thereby enabling the warship to meet its operational deployment commitments.
HIGH MAST WIRE ROPE INSTALLATION AT SHIPYARD
High-mast lighting poles are used to provide high beam, high intensity lighting over a large area at shipyards and other places. These High mast poles vary in height from 25-30 meters. The high mast generally consists of geared motor, lifting ropes with pulleys, rigging mechanisms for pole and luminaries’ fixtures. Dahra Global has recently undertaken major repairs on one such 30-meter-high mast for one of our clients involving replacement of wire ropes and overhaul of the rigging mechanism.
Our team undertook initial site visit to ascertain the maintenance scope requirements and also to understand the HSE requirements for shipyard works. The major factor, as a road block observed was replacement of wire rope which could not be undertaken without lowering the tower pole. Another, hold up was the high wind speed prevalent at the Shipyard. The window for replacement was mere 2 days as wind speeds permissible were below 15 knots for such heavy lift operations. Dahra Global team obtained all necessary clearance & permits via preparation of Risk Assessment & Job Safety Analysis (JSA) documents.
Post LOTO & PTW being received at site, our team lowered the pole using a heavy-duty crane with proper supports on the ground level. The lifting slings & gears used were all certified as per international standards. The team undertook replacement of all 04 wire ropes along with servicing of the rigging mechanisms & levelling of the luminary lights ring.
The lowering/ lifting of the high mast along with the maintenance of associated system, all of which were high-risk operations, was successfully undertaken without any mishap within a duration of 02 days.
INSTALLATION & COMMISSIONING OF ANTI-FOULING SYSTEM
Ultrasonic Anti-fouling Protection prevents marine fouling inside and outside Marine Vessels. Here-in, our team has recently supplied, installed & commissioned a ground-breaking “Ultrasonic” transducer system, that has grown into a complete range of fit-and-forget antifouling solutions for any solid surface that is exposed to marine fouling for the waterjets of a vessel.
Applications – Hulls, Shafts, Propellers, Waterjets, Stern Drives & Steering Gear, Sea-Chests, Pipework, Intakes & Valves, Tanks, Keel-Coolers, Box-Coolers.
The procedure involved initial vessel checks for transducer locations for installation to final commissioning and training of the crew on the anti-fouling system. Our team interacted with the end-user at every milestone, be it during vessel docking, cleaning or final commissioning & undocking. We also prepared an extensive “User Manual” with the maintenance schedules for the system, to enable the crew to operate the new equipment seamlessly. The efforts on the same has been appreciated by the end-user.
The close monitoring and constant interaction with the end-user & vessel crew ensured that the system was installed & operationalized in a short period of 03 days without affecting the “Operational” requirements of the client.
MAGNETIC COMPASS DEVIATION CHECKS FOR GENERAL CARGO VESSEL
Magnetic Compass is a key Navigational aid ensuring safe navigation. Reliable performance of the compass requires inspections at normal intervals. In accordance with the requirements laid down in SOLAS Chapter V, Annex XIII, the magnetic compass inspection & deviation checks entail inspection of components, liquid followed by checks at harbor and sea. In case deviations are observed beyond permissible limits, the same have to be adjusted by the master or by a qualified and certified compass adjuster. One such activity was entrusted on Dahra Global for a general Cargo Vessel on call at Hamad port sailing under the flag of Liberia. The vessel had only a 24-hour turn around call at the port.
Dahra Global was able to facilitate re-validation of the Deviation Card after checks of the compass deviation book held and maintained onboard, with assistance of a qualified Third Party Inspector within 01 day & also undertook training of the vessel crew for filling of compass liquid.
REPAIRS TO MAIN SWITCHBOARD ON CONTAINER VESSEL
One of the Maersk Liner Container Carrier vessel’s had an emergency requirement of repairs to its Main Switchboard, which was damaged due to electrical fire. The job warranted Dahra Global to mobilise our maintenance team on short notice to investigate the damage & ascertain scope of work.
The scope entailed removal & cleaning of nearly half of the main busbars, replacement of two complete sections of starter panels comprising of breakers, contactors & relay units for 14 pumps. Further, inspection of all power & control cabling of the switchboard including providing a modification to enable extending damaged control cables to the starter panels was undertaken. This avoided additional time for procurement & laying of new cables.
Our team of Busbar & Electrical technicians accomplished the above task in a short span by executing the works (24 x 7) for 05 days and completed the testing & commissioning in 02 days. Our timely execution, enabled the vessel to sail with its cargo to next port of call. Dahra Global continues to make major in-roads into the Qatar Marine sector exhibiting our prowess in maintenance and product support to our clientele.
Inclining Experiment of Trimaran Ferry Craft
One of our clients approached us for a solution to enhance the passenger capacity onboard the Ferry Craft. The solution entailed conduct of an “Inclining Experiment” of the vessel followed by preparation of the “Stability booklet” for approval from concerned authorities. Our engineers undertook detailed measurements onboard the craft, prepared a detailed test procedure for the experiment along with calculations for proposed weights. Thereafter, Dahra Global team of marine specialists ascertained the requisite “light ship” load for the vessel. All additional loads were marked and their locations (VCG, TCG & LCG) were marked and indicated on the GA Plan. Post completion, the pendulums & weights were placed as per Inclining Experiment procedure. The experiment was carried out early morning view wind speeds restrictions of less than 6-8 knots. The inclining experiment was completed within 03 hours.
Maintenance of 160 KVA UPS
A major Client sought our assistance for undertaking maintenance & services of their 160KVA UPS systems, which provided supply to the Main Servers of their main administrative building. The UPS system had not been serviced for more than 08-10 years and had additional challenges view majority of the components being obsolete. Further, this task required complete shutdown of main power supply for duration of the system maintenance. Accordingly, the work was planned and executed on a holiday to have minimum power disruption to the Client operations. Our engineers undertook replacement of all aged components & flashed the control modules of the UPS to enable proper functioning.
CORRECTIVE MAINTENANCE ON WORKSHOP MACHINERIES
Corrective maintenance is the category in which the tasks are performed to restore a faulty system or a defective equipment back to normal working state. Herein, glimpses of corrective maintenance undertaken on a workshop machinery viz. Lathe for a client in Qatar are shared. One of our clients at Qatar projected the following issues with respect to a new lathe machine: –
- Heavy vibrations observed on the chuck of Lathe during operation
- Abnormal noise during operation
After detailed inspection of gear train, our team could localize the defect to lock/check nuts securing the tapered roller bearings were not secured tightly & found to be loose. The check nut was tightened to the required torque and clearances and backlash were checked and found correct. Further trials were undertaken and the lathe was observed to be running satisfactory without any vibrations.
MAINTENANCE, OVERHAULING & LOAD TESTING OF ELECTRICAL HOISTS
In a recently concluded project, our team undertook the maintenance & certification of Hoists for a client. All hoists and load carrying appliances are required to be load tested post overhaul / servicing and certified by a Third Party to ensure safe operations. The lifting equipment/ gears are required to be maintained and regularly load tested in accordance with BS 2853/ ASME 30.16.
Our team identified various defects during site survey and proposed a suitable innovative plan including strip-down inspection followed by load testing witnessed by a Third Party. To obviate impact on the on-going operations of the running equipment and movement of hoists, the work was executed utilising mobile scaffolding system.
Scope of the Work entailed: –
- Dismantling of 5T electric hoists (4nos) from beams at a height of 12–15-meter height including strip down inspection followed by overhauling at Workshop
- Dismantling/removal followed by installation of new festoon system for cable
- Surface preparation & painting of runway beams
- Load testing & TPI certification of hoists along with beam at site witnessed by BV inspector
- Testing/ inspection of loose lifting gears used at the site and certification
Post overhauling & load testing of the hoist’s, the system was operationalized & all certificates handed over to the client in good order. Dahra global team is confident of undertaking similar works for repairs, maintenance overhauls of various hydraulic/electric systems for any client in Qatar.
OVERHAULING OF SWIMMING PLATFORM OF YACHTs
Our maintenance team undertook repairs of Swimming platforms for two Yachts during dry-docking at Qatar. The client reported sluggish & uneven rising of the platforms necessitating complete strip-down inspection & overhauling of the hydraulic system cylinders, associated valves & piping. Dahra Global technical team localized the defect related to sluggish response to leakages from the control valves and hydraulic cylinders. Defect rectification entailed dismantling of the hydraulic power pack & components to shop floor followed by overhaul and pressure testing at shop floor to prove efficiacy of repairs.
Post overhauling and installation, normal operation of the platform was restored without any defects. This effort has enriched our experience in undertaking similar works for repairs, maintenance & overhauls of various hydraulic systems for any client in Qatar.
SUPPLY AND INSTALLATION OF SIEMENS SIPROTECH DISPLAY UNIT
One of our esteemed client’s requirement for defect rectification of a 11 KV Substation Protection Relay control and monitoring display unit was executed in a prioritized manner.
The scope entailed supply of items followed by replacement of defective display unit (Siemens Siprotec display unit 7SD5). Even in the present scenario of COVID-19, Dahra Global was able to import the required spares directly from OEM (Siemens) and our team of service engineers successfully replaced the defective component.
Post installation, the functional checks & commissioning was carried out by carrying out all tests of all relays on the display unit. With execution of such project, our teams are confident of undertaking similar works for any client in Qatar.
Survey of Floating Dock at Shipyard
Our team of marine surveyors executed the Annual Deck Deformation survey for one of the largest floating docks in Qatar. The survey requirement was to physically (manual method) ascertain the condition of the deck and measure the deck indentations. The survey was impacted by frequent requirements for docking as well as harsh marine weather conditions. However, despite the odds our survey complete the job successfully involving preparation of a comprehensive survey report, marking of deformations/ indents on Acad drawings & compilation of a photo album, to the satisfaction of the Client.
Supply and Installation of EPT-TX and EPT-RX for 11 KV Soft Starter
One of our esteemed client’s requirement for defect rectification of a 11 KV Soft Starter was executed in a prioritized manner.
The scope entailed supply of items followed by replacement of defective components viz. Electronic Potential Transformer Transmitter unit (EPT-TX) and Electronic Potential Transformer Receiver (EPT-RX) on the Soft starter of three heavy duty Compressor drive motors. Even in the present scenario of COVID-19, Dahra Global was able to import the required spares directly from OEM (Germany) and our team of service engineers successfully replaced the defective components, with minor modifications to suit on-site requirements.
Post installation, the functional checks & commissioning was carried out via complete starting sequence of the soft starter, to the satisfaction of the customer. With execution of such works, our teams are confident of undertaking similar works for any client in Qatar.