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Model upgrade of a large fish factory trawler at "Remontowa"

During summer 2012, another large, complex vessel went back into fisheries service after extensive modernization carried out at Gdańsk Shiprepair Yard "Remontowa" SA. Fish factory trawler Lira returned to fishing business with virtually "as new" status and as an Owner's "showcase" vessel.
Gdansk Shiprepair Yard "Remontowa" SA has a vast experience in repairs of fishing vessels. In the first 50-years of shipyard's history, over 300 major repairs of trawlers and fish processing bases were carried out, with great portion of these being orders coming from Russian Owners.



One of the recent examples of big orders from the Russian market relates to a large, ageing, East Germany built, factory-trawler Lira, which has emerged practically "as new" during works carried out at "Remontowa". Some market observers say such an extensive modernization and re-engining of complex, but ageing factory trawlers could be a potentially viable cost alternative to newbuilding and the Lira case constitutes a model for further similar conversions.
Some 40 tonnes of steel structures have been replaced on Lira, but this was not the major part of the conversion. Practically all trades and divisions available at a highly capable and versatile ship repair yard in Gdansk have been involved in Lira conversion.
Lira's operator - Kaliningrad based fishing company Morskaya Zvezda Ltd. was founded in 1997. At the beginning fishing activity was conducted with use of one rented vessel Marshal Krylov. Each following year saw development of the company fleet with new fishing vessels additions. Lira belonged to the class of largest ships in Morskaya Zvezda fleet consisting of some 15 units, at the time when Lira have been undergoing upgrade at "Remontowa" in 2012.
Given the heavy-duty nature of deep-sea fishing ships operation and the ship's age, it is no wonder that Lira has arrived at Gdańsk based yard with much signs of wear and tear.
Built in 1989 by German yard Volkswerft in Stralsund (now in P&S Werften group), Lira is 120,5 m long, 19.03 m wide, draws 6,6 m and features 7765 gross tonnage and deadweight of 3372 t. She was one of the ships from a successful series of 37 Moonzund class (488 type) trawlers built between 1986 and 1991 and powered by two SKL 6VDS 48/42-AL2 7200 bhp (5294 kW) engines (so this applied also to Lira before conversion carried out at "Remontowa"). Most of these popular fish factory vessels are still in service and some of them have already been converted into research or seismic survey ships or re-equipped with increased freezer capacities.
The wide scope of repairs and upgrade at "Remontowa" included the fish hold rebuilding, along with installation of refrigeration system. The fresh (live) fish tanks were enlarged. Huge amount of work was performed in fish processing and canning plant, which also involved stripping of the whole insulation and replacing it with a new insulation system, with surface panels made of special plastic certified for contact with food products. Also new floors and ceilings were installed in fish factory plant during the ship's stay at "Remontowa". Fish factory plant modifications also involved installation of as many as 10 new freezers, adding to transporters, sorting machines, cartoon handling machines, foil packing machines, deheading and descaling machines and other specialty fish processing and packaging machinery. The entire new refrigeration system was installed by PBUCh (including cooling agent tanks, liquid separators, refrigerating compressors, some 900 m of piping). The ship also got new freshwater and seawater piping systems. Lira has received practically all new electrical, refrigerating and HVAC systems and installations. The crew of the factory trawler, 75 persons strong, will now work in comfort, especially in comparison to pre-conversion conditions.
One of the major tasks to be carried out was the re-engining of a 20-year-old Russian factory trawler. It was accomplished in conjunction with suppliers - Zeppelin Power Systems and Caterpillar Marine Power Systems. In the course of modernization also evaluations of the condition of existing equipment and its links with the drive system with a view to lowering operational costs and increasing efficiency has been carried out. The engine room upgrade included replacement of two main engines with new units, replacement of gearbox, main boiler, air compressors.
Modernizing the ship’s drive system and integrating it into the existing engine room layout was a major challenge. It is utmost difficulty on such kind of ships, packed with various equipment, to trace production process transport paths. It was an important issue as a lot of old equipment had to be removed and replaced with new units and systems, both in machinery spaces and in fish factory area. Timing and chronology (sequence) of operations, not easy to coordinate, was a key to smooth completion of complex conversion.
The new muscle propelling the Lira consists of two MaK type 8M32C main engines each of 4000 kW. The existing gearing, capable of transferring up to 5830 kW was replaced with a "double in-single out" unit from Reintjes. It came out the new engines and gearing along with a new electronic remote control device meant that the existing SKL 8VD 26/20 auxiliary Diesels did not need modification, which is a cost saving for the owners - according to Zeppelin Power Systems. With an available total performance of 8000 kW, two wave generators each of 1500 kW and a drive haft/gearbox/propeller transfer of up to 5300 kW, the trawler now has a powerful drive plant that is tailor-made to demand. Replacement or major repairs also concerned boiler, air compressors, oil separator, waste incinerator, degreaser and many other items of equipment, usually related to the mentioned ones. New engines were installed on new chemical hardened foundation grounting.
During docking typical tasks have been accomplished, such painting and hull maintenance, rudder and propeller overhauls, but also replacing fish finding sonar and echo-sounder transmission and receiving units with new ones in the bottom of the ship.
The vessel departed "Remontowa" late May 2012.



Copyright 2005 Remontowa