mega ice breaker

breaking through one and a half meters of ice demands a mega structure of incredible power the icebreaker please be Hamas keep the world's shipping lanes open during the harshest of conditions making them vital to the global economy now comes the construction of a vessel that can break ice and carry cargo at the same time the Arctic ice breaking container ship it will measure 169 meters way nearly 20,000 tonnes [Music] take 11 months to build [Music] and revolutionize Arctic shipping over the next 11 months a team of 300 engineers and workers from the shipbuilding firm acha yards will combine their efforts here in northern Germany to construct the aqus es 650 a world's first an ice-breaking arctic container ship project manager hands yoke Wenzel will orchestrate delivering this 120 million dollar marvel to the Russian mining company Norilsk Nickel my job is to follow up the project from the very first beginning from the awarding of the contract until the end of the guarantee period of the ships that's right a guarantee Nouriel snickles contract contains a caption they can return the ship for a full refund if it fails to perform as expected for their money Norris nickel will be getting a ship like no other icebreakers rely on three key components a strength II hope a wedge shape and the power to push through solid ice ordinary ships can't risk even brushing past ice but icebreakers can carve a channel 50 metres wide they do it with power and strength most icebreakers have shielded propellers at both the bow and the stern they use their momentum to push their front called the bow up on the ice the bow is specifically designed to break ice it consists of an inclined wedge that forms an angle of about 20 degrees with the ice surface as the icebreaker advances the bow rides up on the edge of the ice until the ship's weight becomes so great the ice cracks as it breaks it's forced downwards along the sides of the band the akka CS 650 also features a revolutionary structure a newly developed propulsion system and a double-acting hull these innovations allow it to carry cargo and break ice most ships sailed bow first not the akka cs6 50 in ice-breaking mode it sails stern first or backwards sailing back would give the ship the power to break through ice one and a half meters thick in light ice conditions or open water the vessel turns 180 degrees and sails traditionally bow first making it double acting the a casillas 650 can navigate icebound arctic ocean routes unassisted year-round not having to hire a separate icebreaker will save its own as millions of dollars a year breaking ice taxes the structural integrity of the toughest ship so icebreakers must be extra strong since the 1960s mining in the Arctic has spurred the construction of ice breakers that can transit as far as the North Pole they not only keep vital shipping legs open they provide the platforms to conduct polar research year-round even the earliest polar explorers used ice-strengthened chips they wrapped iron bands around the hole and nailed metal sheet a to the bow Stern and key [Music] but over time scientists discovered something that makes ice especially dangerous oceans contain different types of ice sea ice forms from frozen ocean water icebergs actually originated on land from freshwater ice shelves or glaciers that carve into the ocean ice breakers must sail safely in all ice conditions [Music] before constructing a 120 million dollar vessel the Agra Arctic research company specializes in Arctic technology development and tests icebreaker models in different ice conditions mica Nene is the head of their state-of-the-art research lab in Helsinki Finland we are a combination of ice model testing facility and a naval architectural company so this is a this is in fact the unique combination which doesn't exist in the world [Music] they've been designing icebreakers for over 50 years what we already had learned here in the Baltic Sea and partly also in the Caspian products was that with some new propulsion devices it was possible to create independently operating cargo ships also for very heavy ice conditions two and a half years ago akka Arctic tested their revolutionary one ship does all design [Music] we sold two knowledge to kill people how much cost saving the implementation of this new technology could could bring to them so they got very interested they could save millions of dollars per year for that kind of money every single part of its function must be tested before and after construction typically in ship design you you do several we call iterations do you have first and one one design and then you then you check everything and if there is something which you think that needs improvements so any improvement always has some other consequences [Music] PACA Arctic's labs have gathered a wealth of knowledge from designing and constructing icebreakers they've tested more than 300 design models and even developed their own model ice natural ice crystals vary in shape and structure depending on the conditions they form under [Music] geophysicist Mecca Michaela makes the ice that akka uses to test their icebreaker designs acha arctic has designed equipment and machinery solely to create very small even ice crystals if we take a fresh water eyes it's really large crystals normally if we take a just a normal state water it has a smaller crystals because there is a salty water insight older actually the crystal size will be even smaller and here we have an even smaller crystal size and that's what was our one of the reason why it's so we this originally patented model ice is the most reliable material to model different ice conditions normally we always make a level ice or ice sheet here and after that we can make different kind of ice conditions we can make a channel with a maze make ice reach of course the ice is also different if you think about where we go we try to make the ice so that it's enough close to the place where actually that boat is going to [Music] this test basin measures 75 meters by 8 meters and 2 meters deep it takes four hours to spray ice onto the saline water and allow it to freeze into a smooth ice sheet we actually spray the water and it's frozen actually on the water seat so normally ice just builds up from the bottom when it's freeze but actually we build it so that it builds upwards meanwhile in an outer chamber the research team prepares the model for testing today we defined ice thickness and we want to know with a certain power level is the vessel able to reach a critical speed first the ice must reach the perfect hardness thickness and texture the team takes several samples to ensure perfect ice in the first test the model ship plows full speed into the Virgin level ice sheet they film this test from above sidon and in this test they break up the ice and let it refreeze to approximate a natural ice field once testing is complete they analyze the data the team then tweaks the design to optimize that ability to break ice then the naval architect sent the designs to Germany so the draftsman can turn them into blueprints project engineer Mateus liniment began working on the akka cs6 52 years ago after it was model tested in Finland we get from our finish that collects basic design which we corrected the design for our building facilities the drawings prepared by the designers described the whole ship from the inside out so we started with a double button it's the area with the ballast tanks worship and also the pipe Tonga was first part which lay down in the dock from the structural drawings they calculate the size and shape of the steel plates when we get the design we have to modify it for our production and this plane shows the blocks the blocks of the shape the team translates the plan into cutting sketches for ordering the steel then they'll assemble the ship in sections [Music] the first section they lay down is the double bottom [Music] the hull is then attached ice breakers can't have weak spots every single element must be strengthened and tested the sea is no place to discover a mistake [Music] September 2007 rookie steel delivers the plates from Finland to a cos twin German shipyard [Music] the 15 rear components will be constructed in bhisma on the Baltic Sea the 12 components making up the ship's front half will be assembled in Varna Munda in North East Germany project manager dr. Wenzel prays nothing holds up construction and the technology performs as the models and simulation predict we are for huge time pleasure to manage all the contracts we have to deliver in this year the whole team of the art is very busy it's not the copy of a standard container ship so they need more time to understand it calls a technique of 6-8 weeks this icebreaker will weigh nearly 20,000 tonnes involve 300 workers consume four and a half million man-hours and cost 120 million dollars it'll contain enough steel to build the Eiffel Tower enough hate to code 12 Golden Gate bridges and 215 kilometers of cable the akka CS 650 will carry containers filled with raw metal ore across icebound seized from the Yenisei River to Murmansk in Russia's Far North high in the Arctic Circle with delivery looming in 10 months Construction must begin on time [Music] the timetable allows no room for mistakes shipyards build icebreakers the same way they build other ships by assembling their component parts into sections then welding the sections together here in the Varnum under shipyard where they're building the front half of the akka CS 650 workers prepare the steel profiles and plates for construction they transfer the plates to the cutting shop to be cut to size in large basins water reduces the toxic emissions produced by the cutting laser these lasers are computer programmed but an experienced engineer supervises each procedure any mistake would derail the ship's delivery some steel plates will come directly here to the milling machine to have their outer edges perfectly straightened in preparation for welding together workers join up to seven sheets to make one huge steel section but other steel plates and profiles must first be bent workers program the desired shape into a robotic vending machine which shakes the metal using 1,000 tons of pressure gantry cranes and multi wheelers move the prepped steel plates and profiles to the dockyard assembly lines each vehicle can carry 400 tons [Applause] gantry cranes handle the heaviest loads [Music] each stands 33 stories high and can lift 600 tonnes they open the warehouse roof so the crane can transfer the ship sections into the drydock the shipyard prefers women to operate the cranes the theory they keep their cool better under stress vital in such a dangerous operation imagine the damage from 600 tons of high-flying steel [Music] after constructing the ship's sections workers attached the pipes and cables to the hull a system of rigs and trolleys gives them complete access everywhere the job takes more than a hundred welders but each knows exactly which section to well no time for mistakes or miscommunication they need to fit this giant jigsaw puzzle together on the first try nor else Nikhil wants to take ownership of their icebreaker ASAP with so much at stake construction continues around the clock it's December and construction has been steaming ahead for three months [Music] backers shipbuilders the plates and profiles into larger sections and hold them here to the paint shop the shop strictly controls humidity and temperature to guarantee the best finish first they blast the steel with high pressure to remove the shock primer then they paint the ship in sections that requires enough paint to fill more than 600 bathtubs after painting they transport the sections to the drydock shop for the next phase of assembly here they're moving the ship's deck house but no one's driving this multiwheel you're looking at the ultimate remote-controlled vehicle each part weighs nearly 400 tons and takes the multi wheelers three hours to move [Music] one month later workers complete the akka cs6 50s component parts now to fit them together [Music] this drydock warehouse towers many stories high and stretches the length of three football fields the door is so huge it takes 45 minutes to open the completion of the double bottom of the ship's front half marks a milestone in the icebreakers construction so workers celebrate with a drydock ceremony the first component they deposit in the drydock is the double bottom they lay coins beneath the keel for good luck they'll retrieve the coins when they flood the ship and present them to the client on delivery but it'll take more than luck to deliver this groundbreaking icebreaker on schedule and in perfect order the ship contains nearly 8,000 tons of steel making it strong enough to go anywhere welding takes over 5,000 man-hours a skilled and dangerous job after completing the shells of the two halves they begin the outfitting [Music] one of the most crucial jobs is installing the engines cranes place 356 ton diesel engines into the back half [Music] each engine can produce 6,000 kilowatts together in one hour they could power 20 American homes for a month this enormous power supply's the ship's main propulsion component a big electrical motor called an Azipod unit this Azipod has a four bladed propeller more than five and a half meters in diameter it's not only big it's versatile it can double as a rudder it rotates 360 degrees around the vertical axis giving the Icebreaker full maneuverability in heavy ice the vessel moves Stern first to break its way through in light ice or open water the vessel turns 180 degrees and sails traditionally bow first a regular container ship is nowhere near as maneuverable it takes twice as far as the akka cs6 50 to stop and turn around the diesel a saccade packs enough power to break through one-and-a-half meters of ice while operating the a casillas 650 can burn 25,000 litres of diesel per hour so it must refuel before every voyage it's an inconvenient and expensive drawback but it is avoidable nuclear-powered icebreakers like the Yamal rarely need to refuel they can remain at sea for up to a year Russia has a fleet of eight nuclear icebreakers [Music] most of her minerals are buried near icebound Arctic Shores so icebreakers are essential for Russia the Yamal is fueled by two nuclear reactors each providing 171 megawatts of power that's enough combined energy to power around 400 American homes for a month built in st. Petersburg in 1992 the Yamal has a big job to keep shipping lanes open she's one of the few surface vessels to ever reach here the North Pole [Music] the only difference between a nuclear icebreaker and a diesel one is its power source three propellers drive the vessel each with four seven-ton blows [Music] the hundred and sixty tonne nuclear reactors that provide the steam for propulsion are encased in steel high-density concrete and water [Music] the nuclear reaction furnishes endless power but yields radioactive waste the main drawback storing and disposing of that waste it takes hundreds of thousands of years to decay to a safe level of radioactivity these ships must cruise in cold water to cool their reactors so they can never visit the southern hemisphere since they'd have to pass through the warm tropics Rush's icebreakers don't just transport minerals to bring in foreign currency the Yamal is chartered for other operations particularly tourism [Music] one of its most popular trips is a champagne reception at the North Pole how many people can say they've been swimming in the polar icecap [Applause] the young man's most important role is providing a platform for exploring resources at the North Pole and transporting these resources will become the acha cs6 fifties urgent job Noren Snickle eagerly awaits delivery of the ACA's CS 650 an ice-breaking container ship that promises to revolutionize their company and save them millions of dollars time is money and these Russian clients don't want to wait a minute over their delivery date seven months into production and the two halves of the ship are complete the back half of the ship sits in the VIS mah drydock the front 72 kilometers away in Varna mana now to join the two halves they tug the front half around the coast to visit the trip should take about 10 hours in bad wings several days once they bring the two halves to the site they'll join them together to begin they flood the drydock but they hit a snag a traffic jam in the drydock a container ship next to the akka cs6 50s back half bars the way they park the ships front half nearby in the outfitting key while they install a jam the container ship must be moved out before the icebreakers front half can come in once the drydock fills with water tugs remove the dock gate and two more tugboats enter they gingerly guide the parked ship out to ensure it doesn't collide with the side of the drydock or the back of the Icebreaker then they float in the front half of the a casillas 650 aided by tugs at the front and back next they pumped two and a half meters of water out of the drydock to float the two halves together it takes three more hours to carry out the precise measurements to connect the two halves this team is checking the real possession of sir for sure related to the aft part and that has to be very accurate we are speaking about centimeters they have to consider and he has to control very accurate pumping the water out of the dark where it is positioned [Music] this is a 3d measuring missile system it's a laser based measuring system very precise you can measure exactly by one millimeter that is floating it can move in all directions and that makes a little bit complicated so they have to lower the four part very controlled keep it under control all the time the front half is still floating while the back half is weighted down with ballast water they'll pump out the water to bring in the front half slowly until the scene becomes parable any mismatch would spell disaster when the two halves are aligned they can weld the ship together [Music] [Music] [Music] once complete they have a whole icebreaker ready for final outfitting and testing now they'll find out if this icebreaker can face Arctic ice 120 million dollars hangs in the balance as dr. Wenzel hopes the a Casillas 650 passes an exhaustive battery of tests tests designed to push every element of this revolutionary ship to the limits of its endurance you know everybody is nervous when we start a C trial but that is part of the journey any malfunctions could set back the delivery by months costing Acker millions of dollars and client Norilsk Nickel both time and money they subject the Icebreaker to an intensive series of tests at the dock it's time to switch on the electrical systems cooling pumps and basic engines it's easier to make corrections here than at sea but before delivery they send the Icebreaker on her first sea voyage her sea trials will last for four days reinholt crawler has the unenviable job of shepherding the a Casillas 650 through final testing we have before c12 made the time schedule and in this it is written in which our we have to made which test for the whole test we have to test the navigation systems we have to make this speed trial the speed is over the contract speed we have made ton in circle and the turning circle for this ship is under 300 meters and that is very very small to put that in perspective the turning circle for a regular container ship for size of the RCS 650 exceeds 500 meters the new icebreaker passes all its trials they carry out the final test the bollard pull test at a special facility here in Norway this test consists of securing the icebreaker to the dock with bollard shackles and running the main propulsion machinery at its highest level for six hours the 10 centimeter wide two-and-a-half kilometer long cables can withstand 600 tonnes of stress imagine tying your car to a gate and putting your foot on the gas for six hours now magnify that by 100 times no ship undergoes a more physically demanding test this was an endurance test six hours for speed as a propeller but the ship is fixed [Music] instead it won 3-0 you almost had 140 [Music] extremely my challenge for the ship itself only thing is about Laettner shaking [Music] everyone hopes the aqus es 650 structural integrity will hold [Music] if anything electrical or mechanical was going to fry or melt it would have done so by now the ship survives now to celebrate it's the end of July and after two years and half a million man-hours of design and construction the ship is ready for delivery to the client they celebrate with a lavish naming ceremony I mean your Mancha boss [Music] dr. Wenzel bids are proud farewell feeling to finish such a sophisticated kind of ships we did the first time yeah that's a good feeling the akka CS 650 becomes the property of Norilsk Nickel [Music] she's now ready to take on the ice clogged seas of the Arctic [Music]

Channel: chocobulletsTV

Views: 3,861,919

Rating: 4.5271778 out of 5

Keywords: mega, ice, breaker

Id: pd1Zgt2lycY

Length: 49min 33sec (2973 seconds)

Published: Sun Jan 13 2013