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COMPA 2GO Composite Repairs for Ships - Service Demonstration, Certification and Market Entry

Periodic Reporting for period 3 - COMPA 2GO (COMPA 2GO Composite Repairs for Ships - Service Demonstration, Certification and Market Entry)

Reporting period: 2020-06-01 to 2020-12-31

The objective of the overall innovation project COMPA 2GO is to commercialise COMPA Repairs solutions for damaged or corroded ship pipes and structures. Using carbon fiber reinforced plastic mixed with epoxy resin, the solution of COMPA Repairs offers cost and time effective alternative to the traditional methods of repair by welding. COMPA Repairs minimize vessel downtime and increase vessel safety by providing a fast and durable repair and eliminating the use of flame. It is applicable to geometrically complex structures and locations difficult to reach.

Through the project, two main solutions have been developed: COMPA Repairs service and COMPA Repairs licence.

The total market for COMPA Repairs makes up about 82 thousand vessels world-wide that are older than 5 years and experience crack or corrosion problems on a yearly basis. These are owned or managed by 890 shipowners and ship operators in Europe, and 1.640 in the World. The market for COMPA Repairs licence are ship repair and maintenance companies represented by 16.500 companies in Europe alone.

The project is performed by the company Alveus, an expert in design, engineering and application of carbon fiber based technology in the maritime industry.
Alveus aims to become a leader in composite and carbon fiber solutions in the maritime industry. Opportunities for further developments of such solutions are manifold resulting in benefits for the applicant as well as for Europe.

As a follow up on the completed SME Instrument Phase 1 project, the specific Phase 2 project objectives were: 1) to complete the development of COMPA repair service in terms of the design and the procedure by successfully completing specimen tests and on-board vessel demonstrations and finalizing eCOMPA Repairs software. 2) to demonstrate the quality of the solution and gain quality approval of COMPA application standard from relevant maritime certification organisations. 3) to develop promotion and sales plan and to establish a network of repair application partners for licensing the technology while ensuring IPR protection and quality management.
During the project period, the company successfully accomplished all mentioned specific objectives.
Technology certification
In the beginning of the project, Alveus defined and selected repair cases of leaking pipes and tanks involving damages caused by cracks or corrosion. The selection of cases was done in consultations with maritime classification society DNV GL which was the starting point of the certification process. Following case-by-case studies, COMPA Repairs received the first certificate “Statement of Feasibility” in July 2019.
The certification process continued with COMPA Repairs Qualification Plan and Threat Assessment which DNV GL accepted and confirmed by issuing the “Statement of Endorsement”.
Two types of specimens were produced: numerous small-scale specimens for demonstration and marketing purposes and 17 large scale specimens for testing as part of DNV GL qualification process. After the conducted tests, DNV GL accepted the test reports and issued the certificate of “Fitness of Service”.
Besides the DNV GL certification, COMPA extended the certificate from Croatian Register of Shipping by demonstrating the technology.
The reporting resulted with an extensive technology know-how document COMPA Repairs Technical Manual.

A direct contact with a number of potential clients was established, the technology was presented with a purpose to arrange onboard demonstrations. During the project, Alveus technical team performed 26 repair cases on board different types of ships: ro-ro/cargo ships, vehicles carrier, cargo carriers, LNG carrier, ferry, sailboat. The cases involved following repairs: pipes and flanges, steel plating and composite structures.

eCOMPA Repairs software
eCOMPA Repairs software - a tool for automatic generation of the patch design for COMPA Repairs was developed and finalised through the project. The software was tested and brought to the stage of readiness for commercialisation.

Sales network
Marketing and sales activities included a number of direct contacts with the target market and resulted with new clients and ship repairs agents that signed a cooperation agreement covering the territory of UK, The Netherlands, Greece, Turkey, Hungary and Brazil.

Visual identity
Visual identity of COMPA Repairs was created, including logo and book of standards. In line with the COMPA Repairs visual, the main communication tools were created: website, social networks (LinkedIn, Facebook, Twitter), presentations, flyers, posters and newsletters. The targeted audience was continuously informed about the news on COMPA technology and case studies with regular press releases, newsletters and posting on social networks.

After careful examination of possible trademarks that were not used in the relevant classes, the company submitted the application for EU trademark protection. COMPA Repairs got a Certificate of Registration for a European Union trademark for engineering services and for the repair and maintenance of various maritime structures. The trademark is registered as a figurative mark containing word elements and is valid for a period of 10 years.

ISO certificate
In 2018, the company implemented quality management principles and received ISO 9001: 2015 certificate issued by Bureau Veritas. The certificate was re-approved in 2019 and 2020 after repeated internal and external audits.

Publications and events
Project results have been published in a scientific article “Study of tube and tank specimens repaired using a carbon fibre reinforced epoxy”. The article has been chosen for a special edition of Maritime Journal – Journal of Maritime and Transportation Sciences, No. 3 2020.
The company has participated in more than 15 events of different kind: scientific conferences, conferences for practitioners and maritime exhibitions. The major event was Europort in 2019, held in Rotterdam where COMPA Repairs had its own stand.
There was a major enhancement in the quality control of COMPA Repairs procedure. Namely, the control of the salt concentration, surface grease and impurities, as well as the surface roughness that are now inspected during the repair by the latest state-of-the-art methods applicable on-board ships in service.
There were new health and safety procedures introduced to the COMPA Repairs. These procedures include measuring poisonous and flammable gases, higher standards for the personal protection equipment. Additional obligatory equipment, such as the head lights, safety vests and the vests to prevent falls from elevated positions. Operations check lists have been introduced for the technicians, project manager and administrative stuff. Threat assessment has been made that involves risks for all known failure modes for patches and parent material (repaired material). Blister resistance (pressure tests) have been made for the pressures above 22 bar as it was done previously for COMPA patches used for pipes. Patches were tested on tank patches (corner and flat plate patches).
For better and faster preparation before the repair execution, developed software eCOMPA suggests the optimum patch design for a specific repair and automatically generates the report for the class approval.
COMPA Repairs application on damaged pipes
A damaged and corroded ship tank before COMPA Repairs application
COMPA Repairs - tank repair before and after
A ship tank after COMPA Repairs application
COMPA Repairs - pipe repair before and after
COMPA Repairs Technical Manual
COMPA Repairs technology layers