17 October 2006
Kiwi innovation is coming to the fore with the building of the inshore and offshore patrol vessels for the Navy, with spin-offs from the project buoying industry in several regions throughout New Zealand.
The four inshore vessels(IPVs), and superstructure modules of the two offshore patrol vessels(OPVs) are being built in Whangarei by Tenix Shipbuilding New Zealand Ltd (TSNZ). TSNZ was established in Whangarei by its Australian parent company Tenix Defence Pty Ltd to meet New Zealand’s industrial commitments to the Anzac Ship Project.
The vessels are being built as part of Project Protector, which will see Tenix Defence deliver seven new ships to the Ministry of Defence. They will be commissioned into service with the Royal New Zealand Navy beginning from early next year.
Ultimately the Whangarei firm not only met its NZ industry quotas through building the superstructure modules for the Anzac frigates, but exceeded them. Their Australian parent company also awarded TSNZ with contracts to build hull modules for some of the later (RAN) Anzac frigates.
Now, TSNZ is fully committed to the four inshore patrol vessels, which will patrol New Zealand’s waters out to 25 nautical miles. Already, two-thirds of IPV1 (to be named ROTOITI) stands on the paved hard standing area at the Tenix sheds in Whangarei. IPV1 is the first of four 55-metre, 350-tonne IPVs to be built, fitted out and launched in Whangarei.
Collectively Tenix Defence and TSNZ has some 60 sub contractors and suppliers throughout New Zealand doing work and providing equipment with a total value so far of NZ$108 million out of the targeted NZ $110 million total New Zealand industry content of the project. The work ranges from structural fabrication and machined components, to electronics and computer software.
The Donovan Group NZ Ltd, manufacturing engineers in Whangarei, is one such sub contractor. Led by Graham Donovan, the family-owned firm has been cutting steel for the OPV and IPV modules, but their particular success story is the adoption of Friction Stir Welding (FSW) technology to join the overseas supplied aluminium panels, which make up the superstructures of the IPVs.
FSW was invented in 1991 in Europe and patented world wide, except in NZ where Auckland University had already published a number of papers on the concept. FSW is particularly relevant to aluminium because it works at a lower temperature, thus better preserving the quality of the metal without distorting the welded plates.
The Donovan Group - which like most NZ engineering firms is very aware of the ease with which clients can contract jobs to Asian companies these days – took the initiative to apply FSW technology to the IPV project. They bought, rebuilt and adapted a Japanese gantry mill for FSW and tendered to Tenix for the welding of aluminium extrusions to form panels for the IPV superstructures. Once Lloyd’s approval was gained, Donovans began the extensive welding necessary to fabricate the side and deck panels for the superstructure modules. In the photo, Brett Donovan stands next to the bed of the Bridge mill that is used for FSW, with his hand on one of the pneumatic rams that were developed by Donovans specifically to clamp the weld material down.
The quality control procedures to set up each weld take time, but with the new technology and their adapted mill, Donovans can weld up to 200 metres per day (in contrast, manual welding might achieve 1m per hour). The technology is relevant to truck decks and railway wagon bodies; Donovans have since bought the rights from the European firm so they can now apply the technology to export contracts within the region.
The hangar, funnel and bridge modules for the Navy’s two OPVs were barged from their construction site in Whangarei to Williamstown in Australia earlier this year. There they will be joined to other modules to complete the construction. OPV1 is to be launched on 18 November 2006 and OPV 2 in May 2007.The two new vessels, to be named Otago and Wellington respectively, will be delivered to the Ministry of defence and commissioned into service with the Royal New Zealand Navy next year.
They will be versatile vessels capable of multi-agency operations in support of national security tasks, and various maritime operations.
The Multi-Role Vessel, which is the largest ship in the fleet of new vessels to be delivered to the Navy, arrived in Melbourne on 24 September after completing a 35-day, 8000 nautical mile delivery voyage from Holland where it was built. During the passage to Australia a variety of weather conditions were encountered including four days of storms in the Southern Ocean/Great Australian Bight.
Project director Gary Collier, who was on the ship at the time, said up to 9-metre swells and sea state 8 conditions were experienced from the stern quarter. “It performed exceptionally well in those conditions,” he said.
In Williamstown, Melbourne, Tenix Defence will fit out the vessel with its weapon and communication systems. The crew will be trained there, and contractor’s acceptance trials held before the ship is accepted by the Ministry of Defence, scheduled for late January 2007. The Multi-Role Vessel will, once commissioned, be known as HMNZS Canterbury.
For more information on Project Protector visit the Navy and Ministry of Defence websites, http://www.navy.mil.nz/ and www.defence.govt.nz
IT at sea – Computer Brokers
Auckland technology integrator Computer Brokers has landed a major contract to supply IT infrastructure to the Project Protector fleet.
The company recently won a competitive tender issued by prime contractor Australian firm Tenix Defence Pty for the supply of computer network equipment for the multi-vessel project.
Computer Brokers will design, procure and install computer networks and core systems on all seven vessels. The project is expected to take 12 months to complete.
Noel Simpson, Computer Brokers’ general manager, says installing IT on military seagoing vessels poses unique challenges. “The installation is in a harsh physical environment and must satisfy strict security measures and standards of safety and health.”
He says the company has already spent over 500 hours on design and the proposal, and expects a team of three Auckland-based staff to spend several hundred more before getting near its first vessel. “An extraordinary amount of planning has already gone into this project. It’s tough fixing problems when you’re 200 miles offshore, so exhaustive lab testing is a significant part of the overall project.”
Computer Brokers has worked with the New Zealand Defence Force and the Royal New Zealand Navy for 10 years. The contract is a significant win in privately owned Computer Brokers’ 20-year history. “It’s not our biggest purchase order but it’s certainly a flagship project in our company’s history,” says Mr Simpson.
Earlier this year the 50 - employee company invested $1.5 million to triple the size of its Albany facility, including the addition of a warehouse to house equipment for large-scale installations.
Fact File – Project Protector
One Multi -Role Vessel
HMNZS Canterbury
- Length: 131 metres
- Speed: 19 knots
- Crew: 53 Navy, 10 Air Force, 7 Army, four from government agencies, up to 250 soldiers, 35 trainees
- Roles: Disaster relief, army transport, naval training, ocean patrol
- In service: January/February 2007
Two Off Shore Patrol vessels
HMNZ Ships Otago and Wellington
- Length: 85 metres
- Speed: 22 knots
- Crew: 79
- Role: Ocean patrol
- In service: April and October 2007.
Four Inshore Patrol Vessels
HMNZ Ships Pukaki, Rotoiti, Taupo, and Hawea
- Length: 55m
- Speed: 25 knots
- Crew: 36
- Role: Coastal patrol to 25 nautical miles
- In service: January, May, September and December 2007.