When vessels are laid up for extended periods, bringing them safely back into service can present significant technical challenges, especially when service records are limited or unavailable. Premier Separator Services was recently appointed by a major ship manager to carry out the re-activation of two refrigerated cargo vessels following a four-year cold layup in the Far East.
The scope of work included the inspection and assessment of all fuel oil and lube oil separators, as well as plate heat exchangers, on board both vessels prior to their return to active service.
The Challenge
Initial inspections quickly identified serious issues across both vessels. Extensive deterioration had occurred during the prolonged layup period, including:
- Missing separator components
- Corrosion and salt damage to control panels
- Major faults within separator running gear
- Damaged auxiliary systems
Due to the scale of the findings, it was determined that all separators would need to be fully stripped, inspected, and rebuilt as part of a complete vessel re-activation programme.
Heat Exchanger Inspection & Repair
At the same time, Premier Separator Services’ heat exchanger team removed all plate heat exchangers from both vessels and transported them to our workshop for detailed inspection.
Following cleaning and crack detection, severe chloride attack was discovered, caused by leaks within the central cooling system. Many of the stainless steel auxiliary plates had suffered pin-holing and were deemed beyond repair, requiring scrapping and replacement.
In total, nearly 2,000 plates were:
- Cleaned
- Crack detected
- Replaced where necessary
- Re-gasketed
- Reassembled and refitted onboard
All heat exchangers were successfully returned to service within 10 days.
Separator Re-Activation
The separator overhaul programme required more extensive work. Over a six-week period, often in difficult conditions, Premier Separator Services fully stripped, inspected, repaired, and rebuilt all 18 separators across both vessels.
This work was made more complex by the long layup period and the absence of historical service documentation, requiring detailed assessment and engineering expertise at every stage.
The Result
Despite the challenges, Premier Separator Services successfully completed the re-activation of two refrigerated cargo vessels, restoring all separators and plate heat exchangers to safe, operational condition. Both vessels were returned to service on schedule and prior to sailing, allowing the ship manager to resume operations with confidence.