IWHC Training Manual

1.1 Purpose

This training manual serves as a comprehensive guide to all aspects of In-Water Hull Cleaning (IWHC), including underwater cleaning operations, waste containment, environmental compliance, and the use of associated hardware and software. It provides detailed procedures for the safe and effective operation of IWHC components—such as diver tools, MarineStream™ software, biofouling filtration systems, and both autonomous and manual cleaning equipment—ensuring regulatory compliance at every step.

The primary objective of IWHC is to optimise vessel efficiency by reducing hull roughness, improving fuel economy, and employing sustainable cleaning practices that prevent the spread of Invasive Marine Species (IMS). Structured as a step-by-step operational reference, this manual covers mobilisation, system initialisation, operational protocols, maintenance, troubleshooting, and reporting. It also functions as a training resource for both new and existing personnel.

1.2 IWHC Overview

The In-Water Hull Cleaning (IWHC) system is a fully integrated solution designed to optimize vessel performance, enhance biofouling management, and uphold environmental compliance. It encompasses a range of specialized components and technologies that work together to ensure effective cleaning, waste capture, and data management while minimizing the spread of Invasive Marine Species (IMS). The system includes:

• MarineStream™ Software: A digital compliance, asset management, and reporting platform that records cleaning operations, biosecurity evidence, and system performance.
• Diver-Operated Tools & Equipment: Manual cleaning tools, suction systems, and hydraulic-powered devices that remove biofouling efficiently while ensuring waste containment.
• Robotic & Autonomous Cleaning Units: Crawler and ROV-based systems for precision cleaning and automated hull maintenance with integrated waste capture.
• Seawater Filtration & Waste Management System: A multi-stage process that filters and disinfects water before discharge, including a Bow Screen Filter, Baleen Filter, Bag Filter Module, and UV Unit.
• Hydraulic & Power Systems: Provide necessary power to cleaning tools, suction units, and robotic systems.

1.3 Safety Precautions

• General Operational Safety: Always check for residual pressure before maintenance; ensure all moving parts are stopped and emergency systems are functional.
• Diver & In-Water Safety: Maintain clear communication, avoid entanglement hazards, work in pairs, and wear appropriate PPE (wetsuits/drysuits, helmets, gloves, weight belts).
• Robotic & Autonomous Units: Keep clear of active units, ensure manual overrides are available, and perform visibility checks before deployment.
• Filtration & Waste Management: Avoid direct contact with waste; use bunds and spill containment measures.
• Electrical & Hydraulic Safety: Isolate systems during maintenance, beware of pinch points, and secure high-pressure connections.
• Worksite & Environmental Safety: Wear required PPE, maintain emergency access, and follow proper waste disposal procedures to prevent marine pollution.

1.4 Target Audience

This training manual is designed for equipment operators, maintenance technicians, supervisors, dive supervisors, divers, and environmental compliance officers involved in IWHC operations.

1.5 Environmental Compliance Overview

IWHC operations must adhere to stringent environmental regulations to protect marine ecosystems and prevent the spread of invasive species. Operators are required to implement biosecurity protocols, monitor water quality, and manage waste in an environmentally responsible manner.

2.1 Description of the IWHC

The IWHC system integrates diver-operated tools and robotic units to remove biofouling efficiently while capturing waste. It employs a dual-method approach: targeted cleaning via divers using handheld tools, and large-scale cleaning via robotic crawlers that attach to the hull and use suction and rotating brushes. This ensures thorough cleaning while preserving anti-fouling coatings.

2.2 Baleen Filter Components and their Functions

• Bow Screen Filter: Captures large debris by pumping wastewater over a screen and directing waste into a catchment bag with an underlying bund.
• Baleen Filter: Provides fine filtration using a 5-micron screen and an integrated spray bar; treated water is collected in a baleen bund.
• Spray Bar: Uses compressed air and freshwater from a dedicated tank to dislodge waste from the filter screens continuously.
• Bag Filter Module (BFM): Houses multiple bag filters to capture residual particulate matter down to 5 microns.
• UV Unit: Disinfects water with ultraviolet light before discharge to ensure compliance with environmental standards.
• Hydraulic Power Unit (HPU): A diesel-powered unit that powers the trash pump to draw water into the system.
• Rapid Reel: Automatically manages suction hoses for efficient deployment and retrieval during operations.
• Hydraulic Trash Pump: Transfers collected waste into the filtration system with a quick-connect design for hoses.
• System Flow Diagram: (Refer to Figure 1 in the manual for a detailed diagram of the filtration stages and flow direction.)

2.3 MarineStream™

MarineStream™ is a digital compliance and reporting platform that records cleaning operations in real time. It supports live video streaming, automatic data logging, and the generation of compliance reports. Integrated with diver tools and robotic units, it enables operators to document pre- and post-cleaning conditions and to verify that all operations meet regulatory standards.

2.4 Diver Tools

Diver-operated tools are essential for manual biofouling removal. These include scrapers, suction devices, brushes, and specialized tools designed to clean niche areas. They are engineered to minimize damage to hull coatings while ensuring that dislodged material is captured within the closed-loop filtration system.

2.5 ROVs

Remotely Operated Vehicles (ROVs) are used for both inspection and cleaning. Flying ROVs are compact drones equipped with high-resolution cameras, sonar, and lighting for hull inspections, while Crawling ROVs attach to the hull and use suction and filtration to remove light biofouling. These reduce diver risk and provide detailed operational data.

3.1 Overview of Implementation

MarineStream™ provides live access to cleaning operations for customers, vessel operators, and regulatory authorities. It enables real-time monitoring of system performance, documentation of biofouling levels, and collection of video evidence for compliance purposes.

• Purpose and Benefits: Provides live streaming, detailed analytics, and automated reporting to optimize cleaning operations.
• Regulatory Compliance: Ensures adherence to IMO, MARPOL, and national biosecurity guidelines by maintaining thorough records.

3.2 Recording and Uploading

Before cleaning operations commence, verify that all recording equipment—helmet-mounted cameras, ROV-integrated cameras, and data loggers—is properly set up. Configure video feeds via OBS and connect them to MarineStream™. Operators can capture live video streams as well as still images for documentation.

3.3 Integrating MarineStream™ with Operational Workflows

MarineStream™ is integrated with MaintainX CMMS to synchronize cleaning logs with maintenance schedules. It automatically logs cleaning sessions, tracks biofouling levels, and generates compliance reports. Data from MarineStream™ is used for performance analytics and to drive predictive maintenance strategies.

4.1 Overview of Diver Tools in IWHC Operations

Diver-operated tools are critical for manual cleaning operations. They allow divers to remove biofouling with precision while ensuring that dislodged material is captured within the filtration system, thereby maintaining compliance with environmental and biosecurity standards.

4.2 Types of Tools

• Pushing and Pulling Hand Tools: Available in polyurethane for soft fouling or hard nylon for tougher fouling.
• Flat Funnel Capture Tool: A suction-assisted device that seals against the hull to capture dislodged material.
• Scourer Pads: Gentle cleaning pads used for delicate surfaces.
• Niche Area Cleaning Tools: Specialized devices for cleaning hard-to-reach areas such as sea chests, thruster tunnels, and cooling intakes.

4.3 Selection Criteria for Diver Tools

Tool selection is based on the type of fouling and the condition of the hull. For soft fouling, gentler tools are preferred, whereas tougher fouling may require more aggressive devices. In all cases, tools must ensure that dislodged material is captured and not dispersed into the marine environment.

5.1 Flying ROVs – Inspection & Surveillance

Flying ROVs are compact underwater drones equipped with high-resolution cameras, sonar, and lighting systems. They are primarily used for hull inspections, capturing detailed images to assess biofouling accumulation and coating integrity.

5.2 Crawling ROVs – Grooming & Cleaning

Crawling ROVs attach directly to the vessel’s hull and use suction combined with filtration systems to remove light biofouling. Their precise movements help minimize damage to protective coatings while ensuring thorough cleaning.

6.1 MaintainX

MaintainX is a cloud-based Computerised Maintenance Management System (CMMS) that digitizes maintenance logs, checklists, emergency procedures, and reports. It provides real-time tracking and scheduling to ensure that all components of the IWHC system remain in optimal condition.

6.2 Mobilisation/Pre-Mobilisation of Filter

Before deployment, complete the following steps:

• Equipment Manifest: Verify all items against the System Equipment Manifest.
• Lifting and Positioning: Use 5m wire rope slings and secure ‘pig ears’ on the container. Coordinate with the crane operator ensuring 1800 mm clearance.
• Spill Bund Deployment: Deploy the PVC spill bund with an anti-abrasion mat (8000 mm x 4000 mm) beneath the system.
• System Levelling: Lower the container onto the bund and mats; verify level using a 1200 mm Stanley level.
• Door Configuration: Secure designated doors (typically Doors 1 and 12 remain closed) to limit water intrusion.
• Catch Bunds for Discharge Chutes: Position catch bunds carefully.
• Solids Catch Frames: Fit frames with fresh bulker bags.
• Power Connection: Connect the electrical lead to the generator.
• Post-Mobilisation Inventory Check: Re-check all components against the manifest.

6.3 System Initialisation

Prepare the IWHC system on-site by:

• Installing and securing the BOH (Bow Screen Hopper) and C2H (Catch Hopper) using holding pins.
• Positioning the Perspex splash unit after removing travel pins.
• Rolling the B2H (Baleen Hopper) into position and securing it with locking pins (using two operators if necessary).
• Installing bunds and sump pumps and connecting discharge lines.
• Connecting the fresh water supply to the bag filter inlet and the main 63A electrical lead.
• Adjusting flow rates over the bow screen for optimal performance.

6.4 Hose/Trash Pump/Rapid Reel/HPU Initialisation

• 6.4.1 Trash Pump Initialisation: Position the Stanley uplift pump ensuring a hose loop of >1 meter; connect the orange tiger tail hose and flood the system to prime the pump (38 L/min; 2200 psi).
• 6.4.2 Hydraulic Power Unit (HPU) Initialisation: Place the HPU on a stable surface near the filtration unit with at least 1 m clearance, connect hydraulic lines securely, and adjust the actuating lever.
• 6.4.3 Rapid Reel Setup and Operation: Verify that the rapid reel is loaded with all hoses, then deploy and secure the reel assembly.
• 6.4.4 Final Checks Before Operation: Confirm that all connections are secure, the hose is fully primed, and power/hydraulic systems are operational.

6.5 Operation

• 6.5.1 System Start-Up: Engage the main isolation switch, verify container lights, and activate the compressor; purge water traps as necessary.
• 6.5.2 Monitoring During Operation: Monitor flow rates, bund levels (using float switches), and sludge pump operation.
• 6.5.3 Spray Bar Functionality: Ensure spray bars are cleaning screens correctly; adjust limit switches and nozzle alignment as required.
• 6.5.4 System Maintenance During Operation: Regularly inspect nozzles, manage alarms, and address any irregularities immediately.

6.6 Daily Shutdown

• Isolate the uplift pump and flush the system with fresh water.
• Run the system clean function to flush the baleen screens.
• Drain the compressor pig completely.
• Clean the Baleen and Bow Screen hoppers using a low-pressure hose.
• Rinse the entire system to remove salt and debris.
• Apply detergent for deep cleaning and pressure wash the bunds.
• Lubricate pneumatic motors and inspect the bulker bag bund and waste management.

6.7 Demobilisation

Follow the daily shutdown procedures, then disconnect all electrical components, remove hoses and support brackets, and stow the system for transport.

6.8 Decommissioning

Reconfigure the system for closed-loop recirculation by modifying discharge lines, running cleaning and rinse cycles for at least 4 hours, and finally draining all bunds and tanks to secure the system for storage or transport.

6.9 Storage Clean

Perform an extensive cleaning cycle by charging the system with fresh water, running several rinse cycles to remove detergent, thoroughly drying all components, applying protective coatings, and storing components with dust covers.

6.10 Cleaning Procedures

• 6.10.1 Proactive vs. Reactive Cleaning: Routine light cleaning is performed proactively to prevent fouling, while reactive cleaning is used after significant fouling buildup with more aggressive techniques.
• 6.10.2 Antifouling Coatings (AFC) & Tiles on Submarines – Types and Damage: Use cleaning methods that match the coating type to avoid damage and document any damage in MarineStream™.

7.1 Routine Maintenance Schedule

Maintenance tasks are scheduled at weekly, monthly, quarterly, and annual intervals. Regular inspections, lubrication of moving parts, and cleaning of filters and hoses are essential to ensure continued system performance.

7.2 Maintenance Processes and Major Cleaning Processes

• Bow Screen Filter: Disconnect unions, remove the bund, clean with truck wash and vinegar, and reassemble with proper reconnection of sensors and float switches.
• Baleen Filter: Disconnect discharge lines, remove the bund, clean interior surfaces and pump connections, and then reassemble ensuring all electrical and plumbing connections are secure.
• Bag Filter Unit: Remove locking rings and filter bags, clean each bag with a high-pressure hose and vinegar solution, allow to dry, and reinstall.
• UV Unit: De-energise the unit, remove and clean quartz sleeves, inspect UV lamps for wear, and reassemble ensuring proper water flow.
• Additional Components: Clean the rapid reel, flush hoses thoroughly, inspect the trash pump for blockages, and rinse the spill bund and anti-abrasion mat.

7.3 Replacement of Components/Consumables

Regularly replace consumables such as filter bags, UV lamps/quartz sleeves, O-rings, lubricants, and cleaning agents. All replacements must be documented in the Consumable Usage Log (Appendix E) to ensure proper maintenance records are kept.

8.1 Purpose

Reporting ensures that all maintenance activities, faults, and operational issues are systematically documented. This supports prompt troubleshooting and provides a verifiable record for regulatory audits.

8.2 Reporting Triggers

Reports must be generated when:

• A system alarm or fault occurs.
• A component failure or malfunction is detected.
• A maintenance activity is performed (routine, corrective, or emergency).
• A consumable is used or replaced.
• A major operational issue (e.g., reduced flow or loss of suction) is observed.

8.3 Reporting Process

Document the issue with the date, time, affected component, and a detailed description. If an emergency shutdown is required, follow the emergency procedure and then submit a formal report using the Reporting Form (Appendix J).

8.4 Documentation and Record Keeping

All reports, logs, and records are maintained in MaintainX for audit purposes. Critical incidents are reviewed during regular maintenance audits to identify trends and prevent recurrence.

9.1 Common Issues and Solutions

• Loss of Suction: Can be caused by airlocks, blockages, disconnected hoses, or internal pump damage. Solutions include reversing small suction hoses, inspecting diver tools and couplings, and managing trapped air.
• Overflow of Bunds: Occurs when inlet flow exceeds limits. Shut down the uplift pump, allow discharge pumps to catch up, and ensure bund capacity is not exceeded.
• Spray Bar Issues: May be due to clogged nozzles or misalignment. Clean or replace nozzles, adjust limit switches, and verify alignment.
• Pneumatic/Electrical Issues: Check for air leaks, loose speed-fit connections, tripped E-stops, and water ingress in control panels.
• Header Tank Overflow: Monitor flow rates and adjust as needed to maintain levels below capacity.
• Screen Blockages: Remove large debris manually and clean screens regularly.

9.2 Alarm/Fault Codes and Responses

• Air Supply Failure: Check compressor operation and inspect air lines for leaks.
• Water Supply Failure: Verify water supply integrity and header tank water levels.
• Power Failure (E-Stop Activated): Inspect and reset E-stop buttons once power is restored.
• Spray Bar Malfunction: Inspect limit switches and adjust nozzle alignment.
• Compressor Faults: Refer to the compressor manual (e.g., Kaeser rotary screw compressor) for troubleshooting.

9.3 System Reset

After addressing the underlying fault, press the system alarm reset button and verify that all system indicators return to normal before restarting the system.

10.1 Emergency Shutdown Protocol

In the event of a critical system failure or hazardous situation, immediately engage all emergency stop (E-stop) buttons to cut power and halt operations. Depressurise the system, isolate power using the main isolation switch, secure all moving components, and follow post-shutdown troubleshooting procedures. An incident report must be completed documenting the cause and corrective actions.

10.2 Electrical Safety Considerations

• Only qualified personnel should perform electrical maintenance.
• Always implement lockout/tagout procedures before servicing.
• Inspect all cables, connectors, and enclosures for signs of wear or water ingress.

10.3 Safe Work Method Statement (SWMS)

The SWMS provides a structured framework for identifying, assessing, and controlling risks associated with IWHC operations. It must be reviewed, signed, and kept accessible on site prior to commencing any work.

11.1 System Capacities and Limitations

Processing Capacity: Up to 60 cubic meters per hour.
Filtration Level: Maintains a threshold between 25 to 50 microns.
Pumping System: Utilizes three pumps for suction, transfer, and discharge.
Variable Speed Drive (VSD): Allows adjustable motor control for energy efficiency.
Limitations: System performance may be affected by power fluctuations, clogging, or incorrect VSD settings.

11.2 Pump Specifications

• Stanley TP08 Heavy Duty Trash Pump: Hydraulic trash pump with a flow rate of 38 L/min, hydraulic pressure of 2200 psi, 3-inch inlet/outlet, self-priming design.
• Tsurumi 40TM2.25 Submersible Pump: Submersible dry-motor pump delivering 1500 L/min; handles solids up to 10 mm; maximum liquid temperature 40°C; submersion depth of 30 m.
• Ultraflow UMDNSS7500/80/3 Submersible Pump: 1500 L/min pump, handles solids up to 20 mm; powered by a 7.5 kW motor; operating at 2800 RPM; suitable for 30 m submersion.
• B3XR-A/B 7.5kW Transfer Pump: Electric self-priming transfer pump with 1500 L/min flow, max pressure of 3.0 BAR, 6 m suction depth, and ability to handle solids up to 24 mm.
• Variable Speed Drive (ACS580): Supports input voltages from 200–240V or 380–480V, operates within a frequency range of 47–63 Hz, and utilizes scalar/vector control for precise motor management.

11.3 Electrical and Water Supply Requirements

Power Supply: 63-amp three-phase power at 415V, 50Hz.
Electrical Enclosures: Must be IP55 or IP68 rated, depending on exposure.
Air Supply: Provided by a Kaeser rotary screw compressor (32 cubic feet per minute) for spray bar and pneumatic functions.
Water Supply: A consistent water supply is critical for the operation of the spray bar header tank and the UV module.

12.1 Legislation, Standards and Codes

IWHC operations must comply with international standards including the IMO Biofouling Management Guidelines, MARPOL Annex V, ISO 20679:2025, as well as regional regulations such as Australia’s National Biofouling Management Guidelines and New Zealand's Craft Risk Management Standard.

12.2 Biosecurity Requirements

Implement pre-cleaning inspections to establish baseline conditions, continuously monitor biofouling levels via MarineStream™, and ensure that at least 95% of dislodged fouling is captured. Post-clean verification must be documented to meet biosecurity standards.

12.3 Waste Disposal

Waste streams (biological material, cleaning residues, process water) must be segregated and securely contained. Disposal must be carried out using approved methods with all treatment records and certificates retained.

12.4 Environmental Monitoring

Regular testing of water quality (turbidity, total suspended solids, pH, dissolved oxygen, specific contaminants, and biological indicators) is essential. All monitoring data must be recorded in MarineStream™ for review and continuous improvement.