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Keppel receives DNV verification certificate for the world’s largest 3D printed shipboard fitting

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Keppel receives DNV verification certificate for the world’s largest 3D printed shipboard fitting. Image: DNV
Keppel receives DNV verification certificate for the world’s largest 3D printed shipboard fitting. Image: DNV
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Keppel Technology & Innovation has received a verification certificate for a 3D printed deck mounted type Panama Chock from DNV, the independent energy expert and assurance provider’s Global Additive Manufacturing Technology Centre of Excellence in Singapore. The component, which is intended for non-class maritime applications, is the world’s largest 3D-printed shipboard fitting.

Panama Chocks are large shipboard fittings for towing and mooring, traditionally manufactured by casting, and are welded to a ship as a supporting hull structure. This component was manufactured by KTI’s partner AML3D using their patented Wire Additive Manufacturing  process which used medium strength structural steel grade ER70S-6 wire feedstock.

The verification by DNV follows extensive research, production and testing by KTI with end users Keppel Offshore & Marine and technology partners AML3D and confirms that the component has met all the primary test requirements in KTI’s project material specification with satisfactory results.

Francois van Raemdonck, Managing Director of KTI, said “KTI has been working on this project with Keppel O&M, DNV and AML3D since 2019, and we are proud to achieve this endorsement. Keppel is transforming the way it harnesses technology and KTI is supporting this by collaborating with Keppel business units to innovate and create value. This is in line with Keppel’s Vision 2030, which includes leveraging advanced technologies to drive growth.”

Additive manufacturing – the industrial equivalent of 3D printing – is an emerging technology which uses 3D model data to fabricate parts, enabling, among other benefits, significant time savings. Wire Arc Additive Manufacturing, or WAAM, has the potential to enable a productivity step change in shipbuilding, and is able to 3D print marine grade metal structures at a scale well beyond other commercially available metal 3D printing technologies.

Aziz Merchant, Executive Director of Keppel Marine & Deepwater Technology, the technology arm of Keppel O&M, said “Keppel O&M is constantly exploring new technologies to stay ahead in the industry and additive manufacturing has the potential to increase the efficiency of shipyard operations. The 3D printing of the Panama Chock shows that large components can be made available with shorter lead times and with equal standards of quality and performance. We are encouraged by the verification and we look forward to exploring how AM can be implemented on a wider scale.”

As part of the qualification process a 1,450 kg Panama Chock was designed and produced to meet international standards and KTI’s project specific material specification. Material yield strength was twice that of the original cast material and was produced with acceptable internal soundness that was confirmed by various non-destructive testing and evaluation methods. The part was then proof load tested to 20% higher load than its design working load. Following the successful load test, non-destructive and destructive testing, the results were reviewed by all parties before the final verification statement was issued.

“It’s pleasing to see further advances within the offshore and marine industry with this development for the world’s largest 3D printed shipboard fitting. Creating trust is critical for the acceptance of 3D printed parts and DNV’s certificate plays an important role in ensuring that this is the case” said Brice Le Gallo, Regional Director, Asia Pacific Energy Systems at DNV.

Dr. Sastry Kandukuri, Senior Principal Materials Specialist, Energy Systems at DNV, added: “I am very happy our Global Additive Manufacturing Technology Centre of Excellence was able to support KTI to reach this milestone. Our team of multidisciplinary experts across DNV with a combined AM service experience of 20,000+ hours look forward to continuing to work together with KTI as they develop and qualify AML3D’s WAM® 3D printing capabilities.”

AML3D Chief Executive Officer, Andrew Sales said, “We’re proud to have been able to partner with KTI and demonstrate the advantages of our patented Wire Additive Manufacturing capabilities in the creation of the world’s largest 3D printed Panama Chock. Additionally, we are equally as excited to see this printed component receive official verification by DNV. This now offers a quality assurance pathway for a wide range of components that can follow a similar validation process. It is a fantastic achievement by DNV, KTI, the AML3D team and our other partners in this project. Working with KTI’s vision for implementing AM has been a further endorsement for our own business model and we’re excited for the future.”

The printed material was subjected to extensive testing by the DNV Singapore Laboratory and the Marinelift Testing & Supply Pte Ltd. Singapore. Researchers and testing engineers utilized advanced microanalysis instrumentation to generate high quality microstructural information and images. In addition, the mechanical and non-destructive testing were assessed and compared against established marine grade cast material.

Throughout the production and testing processes, there was close and collaborative engagement between DNV, KTI and AML3D. Factors such as functional specifications, safety, testing procedures and acceptance criteria were all subjected to scrutiny by experts.

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Container Shipping Lines

Maersk invests in electrofuels startup company

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Maersk invests in electrofuels startup company. Image: Maersk
Maersk invests in electrofuels startup company. Image: Maersk
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Maersk Growth has made a leading venture investment in Prometheus Fuels, a Silicon Valley-based startup with a promising direct air capture-technology to enable cost efficient, carbon neutral eFuels for shipping.

The minority investment in Prometheus Fuels will support A.P. Moller – Maersk’s work to execute on the strategy to decarbonise marine operations.

Maersk expects several fuels to exist alongside in the future fuel mix and has identified 4 potential fuel pathways to decarbonization; biodiesel, alcohols, lignin-enhanced alcohols and ammonia.

The investment supports Maersk’s efforts with electrofuels which include alcohols produced from renewable energy. Along with biodiesel, alcohols including green methanol are feasible fuel technologies.

“Prometheus Fuels is developing a very exciting and innovative technology to produce carbon based electrofuels from direct air capture of CO2. Electrofuels are expected to play a key role for the decarbonisation of shipping and, if scaled successfully, Prometheus Fuels’ technology will address a key constraint for carbon based electrofuels – namely the cost competitiveness of direct air capture”, commented Morten Bo Christiansen Head of Decarbonisation, A.P. Moller – Maersk.

Maersk expects synthetic alcohols and other electrofuels to play a big role in the decarbonisation of shipping, due to its long-term scalability advantages compared to biobased fuels. Produced from renewable energy and water and ambient CO2 from direct air capture, it has the potential to offer infinite availability regardless of geographic scope.

“Our zero net carbon, zero sulphur electrofuel doesn’t compete with food production – it comes from renewable electricity and air so its feedstock is limitless. Our electrofuel offers a truly viable solution to decarbonise shipping – one that can scale and be implemented in time to avoid catastrophic global warming. We’re excited to partner with Maersk, a global leader in decarbonisation in the transportation and shipping industries, to accelerate this transition”, said Rob McGinnis, Founder and CEO of Prometheus Fuels.

Maersk joins a team of investors which includes BMW i Ventures and Metaplanet. Peter Votkjaer Jorgensen, Partner at Maersk Growth, will join the Board of Prometheus Fuels.

“Decarbonization is a strategic imperative of Maersk, so investing in this space is a natural focus point for Maersk Growth and one where we can offer value beyond capital through the expertise and scale of the Maersk organization. Prometheus’ technology has disruptive potential for the green fuel market, and we look forward to contributing as well as learning from this partnership in the years to come” said, Peter Votkjaer Jorgensen Venture Partner in Maersk Growth.

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Container Shipping Lines

Wan Hai Lines holds online ship naming ceremony for new vessels

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Wan Hai Lines holds online ship naming ceremony for new vessels. Wan Hai Lines Ltd
Wan Hai Lines holds online ship naming ceremony for new vessels. Wan Hai Lines Ltd
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Wan Hai Lines Ltd. held ship naming ceremonies for WAN HAI 289 and WAN HAI 290 accompanied by a charity donation. Due to the COVID-19 pandemic, a physical ceremony was replaced by an online one.

WAN HAI 289 and WAN HAI 290 are the 6th、7th vessels in a series of 2,038 teu containerships built by China Shipbuilding Trading Co., LTD., and Guangzhou Wenchong Shipyard Co., LTD. Ms. Emily Wu, Executive Vice President, Corporate Management of FAR EASTERN NEW CENTURY CORPORATION and Ms. Lily Tan, Executive Vice President of SHENZHEN MUNICIPAL RISING AGRICULTURE I/E CO.,LTD, named these two vessels respectively during the ceremony.

The 2,038 teu series is designed with LOA 175m, deadweight capacity of 23,802 mt on 10.5 m draft and a maximum cruising speed of 20.66 nautical miles. The design of 2,038 teu series takes energy efficiency and environmentally-friendly aspect into account. Moreover, all the ships delivered are certified with “Smart Ship” notations by international well-known classification societies. The newbuildings are part of Wan Hai Lines efforts to ensure their continuous pursuit of fleet upgrade in order to provide most quality service to customers.

WAN HAI 289 will be delivered on September 30th at Guangzhou Wenchong Shipyard. After delivery, she will join Wan Hai Lines’ Japan Kansai-Vietnam Service to provide efficient delivery service among the corridor.

In addition to naming the newbuildings, Wan Hai Lines also made charity donations to Sunflower Social Work Services of ZhongShan and Dongguan Social Donation Receiving Station, two local welfare organizations focusing on care for children in difficulty, people with disabilities and the disadvantaged group. The charity donations represent part of Wan Hai Lines motto, “WE CARRY, WE CARE.”, as the company is committed to fulfill its corporate social responsibility, providing quality service to customers and bringing love to the society.

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Intermodal Transport

Samskip acquires Sea Connect UAB in strategic Baltic Sea investment

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Samskip acquires Sea Connect UAB in strategic Baltic Sea investment. Image: Samskip
Samskip acquires Sea Connect UAB in strategic Baltic Sea investment. Image: Samskip
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Acquisition of Baltic shortsea operator once again extends regional links into Samskip’s pan-European multimodal network. European transport group Samskip has broadened its Baltic operations by acquiring shortsea specialist Sea Connect. The Klaipeda-based shipping company, which will be renamed Samskip Sea Connect, offers shortsea services connecting Russia, Lithuania, Denmark, Germany and the Netherlands.

Sea Connect operates three 1A Ice Class container vessels calling twice a week at St. Petersburg and Rotterdam, weekly at Hamburg and at Aarhus sub inducement.

“This acquisition strengthens our position in Russia, in the Netherlands and across a range of key Baltic ports in between,” said Kari-Pekka Laaksonen, Chief Executive Officer, Samskip. “It enhances services for Samskip’s shortsea customers focusing on growth opportunities in Russia and adds opportunities for importers and exporters within the region to secure cost-efficient and sustainable multimodal connections farther afield.”

“Sea Connect has emerged as an exceptionally lean, robust operation offering reliability in quay-to-quay and door-to-door services,” Laaksonen added. Its acquisition consolidates Samskip’s commitments to the Baltic region, following its acquisition of Norlines in 2017 and the founding of a separate Finnish entity earlier this year.

Both Sea Connect Managing Director, Viacheslav Puzemskij and SCS-Russia Managing Director, Anton Larkin remain to play full roles within the new organization, working with Johan van der Pijl, Samskip Regional Director Baltics and Russia.

“This is a win-win for our customers which brings together Sea Connect’s route-specific focus with the opportunities created by Samskip’s extensive multimodal network and values,” said Viacheslav Puzemskij. “Integrating our company with Samskip aligns with the strategic goal we set ourselves in forming Sea Connect to evolve as a trusted partner and grow to serve the full range of customer needs in the Baltic and Russian markets. We assure our present and future clients that a customer-orientated culture will remain in the company, as our most important value.”

Laaksonen anticipates particular growth in unitized volumes connecting Russia and the Baltic states through Rotterdam by rail, barges, vessels all over the Europe, and also greater deployment of Samskip’s expert refrigerated cargo services in St Petersburg. “Russian exporters and importers are likely to be attracted by new possibilities to penetrate markets to the west and south using Samskip’s network of shortsea, rail, inland barge and road services,” he added. Sea Connect’s feeder links with deep sea carriers would also remain.

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