When a vessel encountered critical water ingress through its aft shaft seal system, Subsea Global Solutions was brought in to deliver a fast, effective repair without dry docking. Despite a series of logistical and environmental hurdles, our team mobilized quickly and successfully executed the repair while the vessel remained afloat at the Galveston City Docks.

A Call for Urgent Expertise

The project originated from a referral by Technosub in Veracruz, Mexico, who recognized that Subsea Global Solutions was uniquely equipped to handle complex seal replacements with minimal downtime. Originally planned for Mexico, the repair was relocated to Galveston, Texas due to customs clearance delays requiring a rapid change of strategy and resource deployment.

Subsea Global Solutions Gulf Coast led the project with operational and personnel support from our Vancouver, Curaçao, Trinidad, and Long Beach locations. A single 7-person dive team operated day shifts, managing every phase of the operation.

Scope of Work

Our team’s primary mission was to complete a full aft shaft seal replacement using a ribbon bag habitat system and specialized seal bonding procedures. The process included:

• Rope guard removal and templating of the stern tube

• Fabrication of custom adapter plates

• Installation and blowdown of the ribbon bag habitat

• Seal housing disassembly, seal removal, and bonding of new components

• System pressure testing and reassembly

• Reinstallation of the rope guard and epoxy coating for corrosion protection

Overcoming Obstacles

While the scope was executed as planned, several challenges tested the team’s adaptability:

• Customs delays in Mexico forced the vessel to reroute to Galveston

• Critical equipment was rerouted from other global jobs, including habitat components shipped from Vancouver

• Local fabrication delays arose when a plasma cutter failed, nearly costing a day of progress

• Visibility at the Galveston dock was limited to less than 0.5 meters, slowing underwater welding operations

• During disassembly, congealed silicone grease was discovered between seal chambers, requiring extra cleaning

Despite these setbacks, our team adjusted in real-time—delivering each phase of the project safely and with precision.

Results Delivered

The client allocated six days in port for the repair. While the project ultimately required a seventh day due to unforeseen external delays, our team completed the full scope with minimal disruption to the vessel’s operations. All seals were successfully bonded and tested, the system was reassembled and verified, and the vessel resumed service as scheduled.

Client Feedback and Recognition

The client and their representatives expressed strong appreciation for SGS’s ability to adapt, communicate clearly, and maintain professionalism under pressure. The successful repair not only prevented further water ingress but reaffirmed Subsea Global Solutions’ reputation as a trusted partner for critical afloat shaft seal repairs.

Looking for a reliable partner for complex underwater repairs? Contact us.

Shaft Seal Repair by Subsea Global Solutions

Subsea Global Solutions specializes in class-approved underwater shaft seal repairs that minimize vessel downtime and eliminate the need for dry docking. Our highly trained dive teams and certified seal technicians use OEM-compliant procedures and custom-designed habitats to safely access and replace damaged or leaking shaft seals whether on main propulsion shafts or thruster systems.

We support a wide range of vessels and seal types, offering both emergency response and planned maintenance solutions. Our global network enables rapid mobilization, and our turnkey service includes rope guard removal, seal system disassembly, bonding of new seals, testing, and reassembly all performed to the highest industry and safety standards.

Whether afloat or alongside, Subsea Global Solutions delivers proven, efficient, and reliable shaft seal repairs, keeping your vessel on schedule and in service.

Learn more about our underwater welding services.