World-First on Damaged ZP-21 Thruster Repair
IKAD Engineering recently completed a groundbreaking work on a Niigata ZP-21 thruster repair after an urgent incident in which a client’s vessel ran aground overseas.
A Swift Recovery
With no immediate replacement units available and a lead time exceeding 48 months, the vessel faced extended downtime. IKAD was tasked with returning the vessel to service as quickly and safely as possible.
The thruster was transported to IKAD’s Henderson workshop for assessment, where engineers identified major damage to the mounting flange, resulting in internal gear and bearing misalignment. Material analysis of the thruster cast and hull mounting flange was conducted, and a bespoke welding procedure and repair plan was developed; the first time such a repair had been undertaken on this type of Z-leg thruster globally.
Key Steps in the Repair Process
- Removal of the damaged flange and the manufacture of a new component
- Welding and non-destructive testing to OEM standards
- Heat treatment to relieve structural stresses
- Final machining to meet OEM specifications
- Reassembly and verification of gear mesh and backlash alignment
After Recovery
Once rebuilt, the thruster was transported back to the vessel, reinstalled, and subjected to comprehensive testing including sea trials and full-power bollard pull tests. The client, OEM, and classification authorities were highly satisfied with the outcome, providing full sign-off on the project.
This achievement demonstrates IKAD’s ability to deliver innovative, world-class engineering solutions under challenging circumstances, providing timely, cost-effective repairs without compromising on quality or safety.
A Monumental Team Effort
IKAD would like to extend sincere thanks to everyone involved in bringing this project to life. Your hard work, dedication, and problem-solving abilities were integral to overcoming challenges and achieving this successful outcome.
As we celebrate this milestone, we look forward with anticipation to the next projects in our workshop, continuing to innovate and deliver solutions that push the boundaries of engineering and fabrication excellence.
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