Maximising productivity,

efficiency, and safety in your

shipboard repair operations

By Chris Teoh
Global Product Marketing Manager – Welding and Tools Solution
 Industry 4.0
The Fourth Industrial Revolution, more commonly
referred to as Industry 4.0, is the automation of
traditional practices using modern innovative
technology. Over the years, digitally aware industries
such as automotive, aerospace and manufacturing, have
been leading the drive towards Industry 4.0. Companies
such as Bosch and Ford actively leverage the benefits of
innovation to increase productivity, reduce costs, and
improve efficiency.

“Industry 4.0 technologies were already

transforming manufacturers’ operations before the
pandemic. Now adoption is diverging between
technology haves and have-nots.”�

- McKinsey

Saying that the pandemic has disrupted the global shipping

industry is an understatement.

Let’s do a quick recap of how the sector is currently gripped by What does industry 4.0 mean for the maritime industry?
arguably the most turbulent period in its recent history.
Some players have been embracing the trend, with the advent of increasingly connected ports and
When COVID-19 first hit, it brought the industry to a virtual autonomous ships.5 However, the industry in general is slow to adopt this, and much more is needed.
standstill – shipping demand dropped, vessels were delayed, There is also a need to understand that automation does not only apply to ports. Pivoting to better
port entry was restricted, and more. According to the University solutions will enable ship operators to enjoy the benefits of increased efficiency, improved
of Oxford, the pandemic caused a 10% collapse in maritime productivity, reducing the risk of supply chain disruption and to personnel.
trade in the first eight months of 2020, creating losses of up to
$412 billion.1
The ability of shipping Leveraging on more efficient technology
As of July 2021, around 500,000 seafarers are either stranded
services to continue A key area where improvements can be made is in effective repair and maintenance.
on ships or unable to get on board the vessels, due to travel
undisrupted to transport
restrictions imposed worldwide. There are only a few signs of According to ResearchAndMarkets, the global ship repairing market is expected to grow from
food, energy and medical
the problem getting more manageable, which IMO has $30.16 billion in 2020 to $32.29 billion in 2021 at a compound annual growth rate (CAGR) of
supplies across the
described as a humanitarian, safety, and economic crisis.2 7.1%.6 Why so? The shipping industry is actively exploring ways to be better prepared for an
continents will play a critical
At a time when the industry was, and is still, running out of role in overcoming this endemic world, one where the world is slowly opening up but yet has to be flexible enough to
vessels, containers and resources, ship owners can’t afford any pandemic. Shipping adjust to unforeseen changes.
further potential disruptions to their shipping schedules. They companies will need to Shipboard welding and cutting are critical aspects of repair and maintenance programmes to
are under immense pressure to operate at high capacity and become agile and adaptable ensure vessels are operational. Today’s ship operators can choose from a wide range of welding
minimise time spent on ship repair and maintenance to avoid to this changing situation.”� and cutting equipment, and making the right selection is crucial in improving operations on
losing opportunities. board.
- PwC

2 3
 Wire welding and plasma cutting
Which welding and cutting solutions – the ideal ways forward
are best for you? In many parts of the world, a growing number of ship operators are turning to wire
welding and plasma cutting as safer and more effective solutions to increase
productivity, with a lower total cost of ownership compared to other methods. While
neither process is new, their popularity has increased in recent years. Wire welding
currently represents over 45% of the total global welding consumables sold in the
welding industry over the past decade.

Improved safety and more user friendly

Wire welding and plasma cutting are faster, more user-friendly and efficient than conventional
processes. A wire welding set-up would consist of a power source, a wire welding torch, welding
consumables (typically 5kg or 15kg wire spool) and a gas supply if gas shielded wire welding is
required. This method is easy to set up and safe to use, and much easier to learn compared to
stick electrode welding, which needs the ability to strike and maintain an arc.
Wire welding can be up to 30% faster than stick electrode welding. The suggested travel speed
for stick electrode welding is 75 to 150 mm per minute. Wire welding travel speeds are typically
There is a range of welding options currently available, including oxy-acetylene, stick electrode, TIG and 150 to 250 mm per minute.8
wire welding. For shipboard cutting, the two main options are oxy-acetylene and plasma cutting. As for plasma cutting, its versatility and high heat source mean it can be used to cut any
electrically conductive material such as carbon steel, stainless steel, aluminium, cast iron,
Where time isn’t critical and a high standard of finish isn’t essential, stick electrode welding is the most
duplex, super duplex, Inconel, copper, and titanium. This is a significant benefit for repair works
common welding method.
where materials like aluminium or stainless steel are used on sections like vessel process piping
Likewise, where time savings and quality aren’t vital factors in steel cutting operations, the traditional and tanks, food preparation galley, railings and gratings.
process of oxy-acetylene gas cutting still predominates.

However, it can be difficult and costly to hire an experienced welder, especially when we are experiencing Increased productivity
a significant shortage of skilled welders. In addition to the fact that an average rate to hire a professional is By using wire spools, wire welding allows for continuous welding. This means it can deliver a
now at $15 to $20 per hour7, with limits on the number of crew members on board, finding someone with higher duty cycle (longer arc-on time) and faster travel speeds. In contrast, stick electrode
the skills to perform stick electrode welding or oxy-acetylene cutting accurately and safely can be a real welding requires stops at short intervals to de-slag, change electrodes and restart after each
challenge. 200 to 300mm of welding.

Stick electrode welding requires higher consumption of consumables over deposited weld metal due to Stick electrode welding allows only about 12 minutes of welding for every hour an arc is
generated. By comparison, wire welding can give up to 30 minutes of welding time per hour of
its lower efficiency. This method is restricted by the length of the electrodes, which are limited to 450mm
arc generation.
in length and are disposed of when they become reduced to an electrode stub. The process creates
wastage: about 10% of the electrode stub’s weight ends up as scrap or is unused (a rule of thumb is 1.5kg Meanwhile, plasma cutting uses compressed air and electricity readily available on board to
of electrode mass for every 1kg of weld metal). deliver a ‘cleaner’ cut compared to oxy-acetylene cutting. This process results in more
accurate, versatile, and higher cutting speeds and productivity for steel thicknesses up to
In terms of load, conventional welding and cutting equipment can be heavy to lift and move. The bulkiness 15mm.
poses a problem in the maintenance process, especially when it comes to areas that are difficult to
access.
Lower total cost of ownership (TCO)
While traditional welding and cutting processes are still commonplace, it’s time for ship operators to While the initial outlay for wire welding and plasma cutting equipment may be higher than
consider other methods that are more versatile and portable, ones that will maximise efficiency, conventional standard welding tools, their greater speed, efficiency, performance,
productivity, and safety – which are especially important in this new world we operate in. productivity and reduced waste mean lower overall project costs. In addition, as you would
only use what you need for wire welding, the likelihood of wastage is minimised significantly,
bringing a lower TCO for the project.

4 5
 Unitor new generation
of welding and cutting
equipment
At Wilhelmsen, our Unitor New Generation
Welding and Cutting Equipment enables ship
operators to achieve all the benefits of wire
welding and plasma cutting while
complementing existing tools available on
board, providing greater flexibility and more
options.

The UWW-301 TP is a 3-in-1 multi-purpose

welding machine that performs wire welding,
stick electrode welding, and TIG DC Lift Arc
welding, enabling solid welding results in any
given situation.

The UPC-NEO NG is a high-performance

plasma cutter with an excellent weight-to-
cutting capability ratio for various steel such as Time for a change?
carbon steel, stainless steel, aluminium, or any
The benefits of wire welding and plasma cutting can help ship operators fully meet the
electrically conductive metal.
challenging and changing demands of today’s fast-moving world.
These machines are lightweight, portable,
As mentioned in the article, wire welding and plasma cutting can enhance productivity,
compact, and easy to set up, which makes them
efficiency and safety, and deliver a lower total cost of ownership for projects.
the perfect and most suitable tool to meet the
ever-challenging demands and complexities of Both have been proactively used in leading industries such as automotive, shipyards, and
today’s shipboard welding and cutting works. fabrication for several years. For example, they are even revolutionising opportunities for
industry development when combined with next-generation robotics and automation.

There is no reason why the shipping industry can’t make good use of these benefits. It is
time for us to work towards better maintenance and repair programmes.

6 7
For more information, visit:

or follow us on:

References:
1 https://www.ox.ac.uk/news/2021-04-15-tracking-economic-impacts-covid-19-one-ship-time
2 https://www.imo.org/en/MediaCentre/HotTopics/Pages/FAQ-on-crew-changes-and-repatriation-of-seafarers.aspx
3 https://www.pwc.com/gr/en/industries/shipping-covid-19.html
4 https://www.mckinsey.com/business-functions/operations/our-insights/industry-40-reimagining-manufacturing-operations-after-covid-19
5 increasingly connected ports and the emergence of autonomous ships
6 https://www.researchandmarkets.com/reports/5323258/ship-repairing-global-market-report-2021-covid#src-pos-1
7 https://www.ziprecruiter.com/Salaries/Welder-Salary-per-Hour
8 http://www.haynesintl.com/alloys/fabrication-brochure/welding-and-joining/gas-metal-arc-welding-(gmaw-mig-)