Thrustmaster of Texas  

 

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Message From the President

Joe R. Bekker, President & CEOThank you for considering Thrustmaster of Texas, Inc. for your marine propulsion project. Since the founding of the company, we have consistently provided quality products and service to the commercial marine industry at a reasonable cost.

 

What sets us apart in the marine propulsion industry is our dedication to quality and the commitment to treating our customers as our business partners. Not only do we know the marine market, we actively listen to our customer’s requirements and apply that knowledge to product development and improvement.


With more than 1,000 thruster units in operation around the world, many of them of an exclusive design to suit a particular unique application, we have proven our dedication to design engineering excellence as well as comprehensive service after installation. We hold patents for many of those special design configurations.


At Thrustmaster, we constantly strive for the continuous improvement in the quality and value of our products. While many of the traditional thruster designs available on the market are more than 30 years old, we have taken every advantage of new technology for product improvement. Our thruster designs incorporate the latest state-of-the-art U.S naval technology.


The assurance of quality is reflected in our dedication to the ISO-9001:2000 standards and classification society type approvals of our thrusters.

 

We pledge to operate our company in an environmentally responsible manner. We therefore maintain a broad reaching health, safety and environmental management plan in support of our operations wherever we work.


The dedicated employees of Thrustmaster of Texas share a common passion for building quality products that are known throughout the industry. We welcome the opportunity to serve you for all of your marine propulsion requirements.

 

Happy Sailing!
Joe R. Bekker, President

 

Executive Summary

Thrustmaster of Texas, Inc. is a for-profit, closely-held IRS Subchapter S corporation domiciled in the State of Texas. Founded in 1984, by its president, Joe R. Bekker, the company has grown to a world leading manufacturer of heavy duty commercial marine propulsion systems. Products comprise all types of main and auxiliary marine prolusion equipment including deckmounted propulsion equipment, thru-hull azimuthing thrusters, retractable thrusters, tunnel thrusters, and portable dynamic positioning systems.


Thrustmaster has a complete and experienced engineering staff which designs all of the thruster and control systems. Most of the key personnel have doctorate or advanced level engineering degrees. State of the art computer aided drafting and manufacturing as well as solid modeling and finite element analysis systems are used in the design of the products.

 

Reliability of the Thrustmaster marine equipment is proven by the more than 1,000 propulsion units and thrusters in service around the world. Thrustmaster propulsion equipment has been type-certificated and approved by every major classification society as well as the U.S. Navy, U.S. Coast Guard, and numerous foreign navies. Thrustmaster is ISO-9001:2000 certified by the American Bureau of Shipping (ABS).


Current annual revenues are in excess of USD 100-million with a current production backlog of well over USD 150-million.


Current production facilities include a 90,000 square foot manufacturing facility and 20,000 square feet of design and administrative space located in northwest Houston, Texas. Thrustmaster is currently in the process of constructing a new facility on a 60 acre tract near its present location. The new facility includes a 200,000 square foot thruster factory, a separate 40,000 square foot engineering design and administrative center, and a large outdoor in-water test facility for testing of large thrusters including the testing of thruster underwater mount and dismount integrity. Thrustmaster is a medium sized business by U.S. employment standards and employs an average workforce of more than 150.


Thrustmaster’s Service Department comprises a complete staff of highly experienced field service engineers operating from the Houston facility, as well as several forward-based service engineers in strategic locations around the world such as Dubai, China, Singapore, and The Netherlands. The Service Department can be reached by telephone at any time day or night regardless of local time. Service engineers can be dispatched within 24 hours to any destination in the world. All service engineers are qualified to supervise installation, perform start-up and commissioning procedures, and attend dock and sea trials. A dedicated Training Manager is available for customer training at the Houston facility or anywhere in the world.


Thrustmaster maintains a large inventory of spare parts at its Houston manufacturing facility as well as in strategic locations such as England, Dubai, China, Singapore, and The Netherlands. Spare parts can be shipped within 24 hours to any location in the world.

 

 

1. General History

Established in 1984 by its current president, Joe R. Bekker, Thrustmaster of Texas, Inc. has grown from a small manufacturer of outboard, deck-mounted propulsion units to a worldwide leading manufacturer of marine propulsion systems. From the first order for 13 deck-mounted propulsion units for the U.S. Army Corps of Engineers and a follow-up order for the U.S. Navy, Thrustmaster has continually grown and expanded its propulsion systems designs as well as its engineering and manufacturing capabilities. In ten years, the company had more than quadrupled its size and was rapidly growing into a new second facility.

In 1995, Thrustmaster moved to its current facility and expanded its workforce to accommodate the growing demand for Thrustmaster’s thrusters designed for both main propulsion and propulsion assist. In the following years, the engineering department was upgraded with hiring a new chief engineer who specialized in rotating equipment manufacture, the installation of customized mixed-mode manufacturing software specifically detailed for Thrustmaster’s products, and the addition of state of the art CAD/CAM and FEA engineering software.

Thrusters for dynamic positioning became one of Thrustmaster’s prime examples of excellence in both engineering design and manufacturing.

In 2001, a new General Manager significantly improved both the manufacturing efficiency and quality of field service. In 2002, Thrustmaster received certification as an ISO-9001 qualified marine equipment manufacturer from the American Bureau of Shipping (ABS) Quality Systems division. In 2003, Thrustmaster upgraded its ISO quality system to the ISO-9001:2000 standard. ABS issued a Certificate of Manufacturing Assessment Certificate and type approval certificates for Thrustmaster’s standard tunnel thrusters.

In 2006, Thrustmaster began the process of constructing a new expanded facility to support the increase in sales which now exceed USD $100-million annually. Thrustmaster now manufacturers thruster systems up to 8,000 horsepower (6,000 kW). Orders for main propulsion and dynamic positioning thrusters for the commercial marine and offshore energy sectors as well as military fleet improvement programs continue to make Thrustmaster a world leader in marine propulsion.

 

Thrustmaster Chronology

1984

Thrustmaster of Texas, Inc. is founded in Houston, Texas, by Joe R. Bekker who is still the President and CEO of the company.  The first order, a self-contained diesel-driven propulsion unit for mounting on the deck of a barge, is produced for the U.S. Army Corps of Engineers.

1985

The U.S. Navy orders four propulsion units for a crane barge.  Hydraulic tunnel thrusters are produced for several military and commercial customers.

1987

The U.S. Army orders thirteen self-contained diesel-hydraulic propulsion units for floating causeway application.

1988

The first Portable Dynamic Positioning System (PDPS) is installed on a treasure hunting vessel, the Arctic Discoverer, which successfully locates the S.S. Central America and recovers an estimated USD 150-million in gold.  Ellicott dredges are outfitted with fixed hydraulic podded thrusters.  A radio-controlled propulsion unit is installed on a bow boat used by Breathwit Marine Contractors for better navigation of barge trains through rivers and canals.

1989

Clean-up contractors order fourteen diesel driven propulsion units for the Alaska oil spill in Valdez, AK.  A car ferry crossing the Mekong River in Laos is provided with diesel-hydraulic Thrustmaster propulsion units.  Breaux Brothers orders aluminum tunnel thrusters for crewboats.

1990

The U.S. Army Corps of Engineers continues to buy propulsion units of different sizes and configurations.  Hydraulic tunnel thruster business grows rapidly for use in OSV’s, dinner cruise vessels, river casino boats and tugs.  Thrustmaster moves to larger manufacturing facilities.

1991

The first Thrustmaster azimuthing Z-drives for tug boats are installed at Bernert Tug and Barge Lines.  The Navy of Pakistan joins the growing list of military users of Thrustmaster propulsion units.  More units are shipped to customers in Guyana, Korea, Indonesia and Singapore.  Thrustmaster rapidly is becoming a major thruster manufacturer in the world commercial marine market.

1992

Alcatel buys a PDPS for a cable lay barge in Thailand.  Matson Navigation orders an azimuthing retractable stern thruster with radio control for one of their towed ocean-going barges.  Baker Marine in Singapore orders azimuth drives for self-propulsion of a jack-up rig.  The U.S. Air Force buys Thrustmaster propulsion units for offshore bases.  The U.S. Navy orders propulsion units for torpedo testing barges.  Thrustmaster is elected “Exporter of the Year” by the U.S. Small Business Administration.

1993

Many casino boat projects with through-hull azimuth Z-drives and large hydraulic tunnel thrusters.  The Marine Spill Response Corporation (MSRC) orders seventeen self-contained diesel-hydraulic propulsion units with integrated pilot house, mast, oil skimmer drives and many other features.  Global Industries installs retractable azimuth thrusters in one of their large pipe lay barges.  Sales now exceed ten million dollars.  Thrustmaster doubles its manufacturing space.

1994

The Navy of Pakistan orders more self-propelled deck mounted units for barges.  The U.S. Navy Underwater Warfare Center (NUWC) orders diesel-hydraulic propulsion units for sonar research program.  Thrustmaster continues to supply many tunnel thrusters for casino boat projects.  Western Geophysical orders diesel-hydraulic propulsion units for operations in Kazakhstan. 

1995

Thrustmaster Z-drives and podded non-steerable drives are used on long-range trawler yachts built by Cape Horn Trawler Corporation and others.  Edison Chouest Offshore buys Thrustmaster steerable drop-down thrusters for station-keeping of their large aluminum fast supply vessels.  Many diesel-hydraulic propulsion units are built for brown water barge applications for river transport in Alaska, South America, Africa and the Far East.

1996

Pirelli orders PDPS thruster system for cable-lay barges used in shore approaches and shallow water trench-lay-bury operations.  International business is growing fast with thrusters for OSV’s in Malaysia, fishing vessels in Peru, transport barges in Ecuador, fast ferries in Australia, an offshore construction barge in England, a SWATH vessel in Hong Kong, a cruise vessel on the Thames River, car ferries in Chile and Egypt, a tanker in South Africa and split-hopper barges in Indonesia.

1997

U.S. Navy uses the PDPS for diving support. Tug projects in Mexico and Venezuela, many OSV and PSV thrusters for dynamic positioning, retractable azimuth thrusters for tanker application.  Thrustmaster’s Chief Engineer, Dr. Shaw Dou, Ph.D, brings ANSYS Finite Element Analysis into the company.  Thrustmaster moves to a larger factory.

1998

Seacor Marine orders retractable bow thrusters for their large aluminum crew/supply vessels.  Delba Maritima in Brazil orders PDPS thrusters for dynamic positioning conversion of an OSV.  Western Geophysical buys large propulsion unit packages for survey barges at Alaska’s North Slope.  Refinery Terminal Fire Company in the Port of Corpus Christi orders azimuthing thrusters to dynamically position a large fire-fighting barge.  Many thruster orders from all over the world.  Thrustmaster now the largest thruster manufacturer in the U.S. and one of the largest in the world.

1999

Seacor Marine places new orders for retractable thrusters for its new-build fleet improvement program.  A second PDPS delivered to Pirelli for cable-lay barge conversion to dynamic positioning.  Hydraulic tunnel thrusters are ordered by numerous shipyards for tuna fleet expansion in Mexico.  U.S. Army Corps of Engineers continues to order deck-mounted propulsion units.  The first jet thruster delivered to Baltimore Marine Industries.

2000

At the turn of the Millennium, Thrustmaster is well established as a world leading manufacturer of marine propulsion equipment for the 21st Century.  Several large vessels are converted to dynamic positioning class using Thrustmaster electric or hydraulic thrusters.  More harbor tug operators order azimuthing Z-drives for new tugs and retractable azimuth thrusters for upgrades of older tugs.  Several PDPS ordered for barge conversions operating in the Pacific Rim.

2001

Owen Traylor joins Thrustmaster as General Manager who introduces significant improvements in customer service.  Many PDPS systems are ordered by customers all over the world. 

2002

Thrustmaster receives ISO-9001 certification. Builders of OSV’s crewboats, tugs, ferries and military vessels place orders in record numbers.  Six 2,000 HP azimuthing Z-drives delivered for escort tugs on contract to the U.S. Navy for surface ship and submarine docking services.  Seacor Marine continues their fleet improvement program with Thrustmaster’s thrusters.  Thrustmaster expands its manufacturing facilities again.

2003

Thrustmaster’s quality system is upgraded to ISO-9001:2000 by the American Bureau of Shipping (ABS) Quality Evaluations.  Thrustmaster continues to grow into a world leading marine propulsion manufacturer. Thrustmaster wins contract to provide thrusters for the U.S. Army Logistical Support Vessel (LSV) program.

2004

Continuous but controlled growth leads to record numbers of thruster orders.  Many azimuthing Z-drives ordered for ASD tug fleet improvement programs.  Egyptian government places an order for 270 self-contained propulsion units.  More PDPS ordered by operators in the Pacific Rim.  Thrustmaster wins contract to supply thrusters for the U.S. Navy’s Littoral Combat Ship (LCS) program.

2005

ABS Tunnel Thruster CertificationThrustmaster receives ABS Manufacturing Assessment Certificate and "Type Approval Certificates" on standard models of hydraulic tunnel thrusters.  PDPS hydraulic thrusters now produced up to 2,000 horsepower each (1,500 kW).

2006

Many hydraulic thrusters and self-contained power units of 1,000, 1,500, and 2,000 horsepower ordered for various conversions to dynamic positioning.  U.S. Military Sealift Command leases PDPS for deck barge.  Large azimuthing thruster orders for drilling platforms. Thrustmaster now producing thrusters up to 8,000 horsepower (6,000 kW).

2007

Thrustmaster receives record number of orders for large electrically-driven thrusters for drilling applications.  Design of the new 200,000 square foot thruster factory begins.  Thrustmaster receives “Subcontractor of the Year Award” from the U.S. Small Business Administration for its work on the U.S. Navy LCS program.  Annual sales now exceed USD 100-million. Computational Fluid Dynamics (CFD) programs are added to Thrustmaster’s suite of design tools.

2008

Thrustmaster continues forward with new factory breaking ground in May 2008.  Two retractable DP azimuth thrusters are installed in the Seacor Cheetah high speed catamaran crew boat.  Signs new contracts leading to mechanical geared drives of 5000 to 6000 hp while continuing to produce record numbers of Portable Dynamic Positioning Systems.  Field offices are opened in Europe, the Middle East, and Singapore.

 

2. Business Model

Mission Statement

Thrustmaster of Texas, Inc. aims to be a leading manufacturer of marine thrusters all over the world. We believe we can achieve this by:

  • Optimizing product configuration for each individual customer application;
  • Producing high quality products on time and at a fair price and profit level;
  • Providing comprehensive after-sales service;
  • Continuous product improvement based on customer feedback; and
  • New product development to address changing market needs.

General Business Model

The closely controlled structure of Thrustmaster of Texas, Inc. ensures the superior quality of its products and services, each of which is tailored to meet the individual customer’s specific requirements. Its corporate framework also guarantees prompt, continuing maintenance and support services of each product to ensure the repeated satisfaction of its customers.

Thrustmaster’s established reputation as a leader in the technically complex marine propulsion industry, combined with its comprehensive quality management program, enables Thrustmaster to achieve project objectives efficiently, consistently and without unnecessary engineering changes, delays or cost overruns. The following are just a few of the ways Thrustmaster ensures that its customer’s project will meet their expectations:

  • Know the Industry
    Thrustmaster is actively involved in all aspects of the marine industry including the offshore service and supply, oil and gas exploration and production (OGE&P), cargo, ferry and passenger vessel sectors as well as the military deepwater and littoral operations. Moreover, it is involved with many marine, engineering and manufacturing professional societies to keep current on the latest technology and industry requirements.

  • Know the Regulations
    Thrustmaster’s experienced staff has expert knowledge of the complete spectrum of marine regulatory issues with respect to marine propulsion, including IMO, USCG, SOLAS, IMCA, ADC, etc.

  • Know the Classification Societies
    Thrustmaster works very closely with all major marine classification societies to ensure that its propulsion products meet the most exacting standards in accordance with best marine engineering practices. ABS, DNV, BV, LRS, GL, and CCS have all approved Thrustmaster propulsion products for commercial vessel and offshore applications.

  • Have a Passion for Quality
    Thrustmaster understands that its products are the backbone of many ships, crews and businesses worldwide. Thrustmaster’s extreme attention to product quality is crucial to the success of its customers and deeply ingrained into its corporate culture. Thrustmaster employees share a common passion for building quality products that are known throughout the industry.

  • Senior Management Involvement
    Senior managers review all designs, production schedules, and quality plans to ensure the best possible project management. Thrustmaster measures its success on how consistently it meets project deadlines, control costs, and maintain customer satisfaction.

  • Customers are Business Partners
    Thrustmaster looks at its customers not merely clients but as and as an integral part of the team. Instead of merely taking the customer’s specification and designing a product, Thrustmaster involves the customer at every step of the project, explaining the various engineering options available and compliance issues, thus allowing the customer to make sound technical and business decisions. By viewing the customer as a partner in each project, Thrustmaster ensures that the customer’s expectations are well met.

CONTINUITY OF OPERATION PLAN (COOP)

Thrustmaster maintains an industry standard Continuity of Operation Plan (COOP) as part of its overall risk management strategy. Business units and manufacturing capacity are segregated or duplicated where necessary to ensure that a plant casualty will not result in a catastrophic interruption of business operations.

Memoranda of understanding with suppliers as well as machining and manufacturing subcontractors allow for the shifting of logistical requirements to off-site facilities in the event of an interruption.

More than sufficient builder, property, and liability insurance coverage is in place to ensure that risk is adequately financed.

 

3. Organization & Capabilities

A. Organization

Thrustmaster of Texas, Inc. is organized in accordance with the chart which may be found in Appendix A. Generally, the organization consists of the President which operates as the Chief Executive Officer (CEO) of the company. Because the organization is a closely-held private Subchapter S company, there is no board of directors and all executive decisions manifest in the President/CEO.

A General Manager functions as the Chief Operating Officer (COO) and oversees the day to day manufacturing and engineering operations as well as the administrative departments.

Engineering is overseen by the Chief Engineer who supervises all engineering personnel and reports to the General Manager. The Chief Engineer manages the design of thrusters and components as well as the assessment and specification of processes required to manufacture the thruster and formulate the quality plan for each project. The Chief Engineer is assisted by a number of Engineering Managers and Lead Design Engineers.

B. TECHNICAL CAPABILITIES

Project Management

Thrustmaster of Texas, Inc. has assembled a well-qualified and experienced project management team of marine propulsion professionals which is a highly-skilled and diverse group. From the first enquiry to the finish of dock and sea trials, each project has a hand-picked team assigned to ensure complete customer satisfaction with design, installation, performance, and service from its products.

The engineering project management team ensures that a project is designed, assembled, tested, and delivered in exact accordance with the customer’s technical requirements and specifications. Moreover, the management team ensures optimized allocation of company resources to ensure on-time delivery without cost overruns or unnecessary delays. The custom mixed-mode manufacturing software allows Thrustmaster to continuously monitor the exact milestone of each project and alerts the project team to any anticipated difficulties allowing for intervention and correction before any manufacturing problem can mature.

Thrustmaster uses the Program Evaluation and Review Technique (PERT). The PERT method is incorporated with the Critical Path method and the project is tracked on a GANTT chart backed up by custom designed project management software.

Since its inception, Thrustmaster has been continuously involved in large commercial and military marine equipment deliveries which require precise and dedicated project management skills. Examples of large scale projects include the U.S. Army’s Logistical Support Vessel (LSV) program, the U.S. Navy’s Littoral Combat Ship (LCS) program, numerous Dynamic Positioning (DP) installations and conversions, and OSV/PSV fleet improvement programs.

In 2007, Thrustmaster of Texas, Inc. received the prestigious Subcontractor of the Year award on behalf of the Small Business Administration for its project management of the U.S. Navy LCS thruster program at General Dynamics Bath Iron Works (GDBIW) shipyard.

Thrustmaster’s dedicated engineers, project managers, engineering support staff, and field service engineers have proven themselves over and over again as highly capable, skilled, and professional marine propulsion team. No matter how large or small the project, Thrustmaster’s project anagement experience is ready to serve the customer to ensure quality design and timely delivery.

Thruster Design, Manufacture, Assembly & Testing

General
Thrustmaster has extensive experience in the turnkey development of complete propulsion systems for specialty applications. This includes the definition of operational requirements, translation into design parameters, selection of a suitable concept and configuration, equipment design, manufacturing, purchasing of commercially available system components, packaging, testing, and assistance in installation, commissioning, dock trials, sea trials and ongoing logistical support for the system.

One of Thrustmaster’s greatest strengths lies in systems analysis. The company has the experience, ability and technology necessary to apply its propulsion systems creatively to a multitude of challenging applications. Thrustmaster engineers routinely design new thrusters to achieve a perfect match between thruster features, vessel geometry and operational parameters.

Engineering Design
Thrustmaster’s state-of-the art thruster designs are developed using the latest Computer-Aided Design (AutoCAD) software, ANSYS Finite Element Analysis (FEA), modal analysis, 3D solid modeling and strain gage testing under load. Hydrodynamic studies are performed using HydroComp NavCad, and CD-adapco CFD software.

Fabrication & Machining
Fabrication facilities use computer controlled plasma and flame cutting machines as well as modern flux-core welding equipment for both aluminum and steel construction. Machining tools include large horizontal boring mills, vertical turret lathes, manual and CNC engine lathes, as well as both vertical and horizontal CNC machining centers. Welders are certified to meet all shipbuilding classification society and regulatory authority standards including ABS, DNV, BV, LRS, CCS, and GL. Non-Destructive Testing (NDT) is a routine quality control procedure and includes liquid penetrant, magnetic particle, eddy current, and ultrasonic inspections as well as radiographic examination.

Assembly
Every Thrustmaster product is assembled by experienced production personnel and subjected to rigorous testing prior to shipment. A highly educated and well trained workforce has been developed at Thrustmaster. The company devotes a great deal of time and resources to upgrading personnel through ongoing educational programs. Dedication to the goal of constant improvement has greatly increased the professionalism and efficiency of the people who run the company’s manufacturing operations.

Factory Acceptance Testing
The robust design of Thrustmaster’s marine propulsion equipment incorporates fabricated housings that are subjected to ultrasonic, liquid penetrant and hydrostatic testing. Full load and torque are applied to verify gear contact patterns of assembled units. Each thruster is subjected to extensive running and functional testing prior to shipment in accordance with the project quality plan an the company’s quality management system.

Subcontracting
With its location in Houston, Texas, the heart of the offshore industry, the nation’s fourth largest city and with the largest tonnage port in the USA, an excellent support infrastructure exists within the city. Houston has an abundance of job shops available for subcontracting of fabrication, machining and special processes.

Thrustmaster has established many long-term relationships with its local subcontractors who are thoroughly familiar with Thrustmaster’s products and manufacturing practices. Because of these long-standing relationships, the volume of work and quality control, Thrustmaster will not have to submit subcontracted fabrication, machining or finishing work to unproven or unknown
vendors.

Quality Assurance & Control (QA/QC)

Thrustmaster is certified to ISO-9001:2000 standards by ABS Quality Evaluations. All products are subjected to rigorous inspection in accordance with a quality and engineering review plan developed specifically for each project. All quality records are maintained and assembled in a Manufacturing Data Record Book for each project.

A dedicated Quality Assurance and Control (QA/QC) manager ensures that the procedures promulgated by the Quality Assurance Manual (QAM) are strictly followed during the manufacture of each thruster in accordance with the project quality and engineering review plan. The Quality Manager supervises a well-trained staff of quality line inspectors.

Health, Safety & Environmental (HSE)

Thrustmaster maintains a strict Health, Safety and Environmental (HSE) policy at its facility and on-site facilities of the customer. The purpose of the HSE policy is to integrate a safe, healthy, and environmentally responsible culture into all company operations.

Thrustmaster strives to send every employee home healthy at the end of each day. To accomplish this goal, Thrustmaster has instituted a safety management system built on comprehensive and structured programs designed to reduce accidents and eliminate injuries at the Houston facility and at the customer’s facilities or while embarked on board ship.

Environmental management includes programs that provide oversight of hazardous waste management, chemical conservation and pollution prevention, emergency preparedness and planning.
A dedicated HSE manager is employed to administrate the HSE Management System and provide employee training. The HSE manager is assisted by a number of safety inspectors as well as an organized HSE committee.

Information Technology (IT) System

Thrustmaster’s Information Technology (IT) system is state of the art and incorporates both local and wide area networks and VPN capabilities within the company. For its mixed-mode manufacturing method of operation, Thrustmaster uses a state of the art custom software application that manages each project from inception though fabrication, assembly, and factory acceptance testing and
is capable of detailed fiscal, operational, and maintenance reporting.

A comprehensive Critical Application Disaster Recovery Process is part of the company’s Continuity of Operations Plan (COOP). All critical data is stored on mirrored hot-swappable drives on Thrustmaster servers. The server’s automatically backup critical data daily to removable backup tapes and the daily backup tapes are stored off-site to ensure continuous availability of all project critical data and records.

Human Resources (HR)

Thrustmaster maintains a diverse and productive workforce. A particularly effective means for reducing labor-relations problems before they arise is to hire committed workers with positive attitudes. By developing a reputation as great places to work, Thrustmaster attracts many potentially productive workers who take pride in their work, in their company and in what they produce.

In addition to excellent competitive health and retirement benefits, Thrustmaster has in place a variety of programs that have resulted in employees knowing that they work for a great company and this has resulting in very stable labor relations within the company. There has never been a strike, work stoppage, work slowdown, or act of intentional sabotage at the company.

Field Service Engineers and Spares

Thrustmaster’s Service Department comprises a complete staff of highly experienced field service engineers operating from its Houston facility, as well as several forward-based service engineers in Dubai and China. The Service Department can be reached by telephone at any time day or night regardless of local time. Service engineers can be dispatched within 24 hours to any destination in the world. All service engineers are qualified to supervise installation, perform start-up and commissioning procedures, and attend dock and sea trials. Each engineer is specially trained in diagnosis, troubleshooting and repair and can train shipyard personnel and vessel crews. A dedicated
Training Manager is available for customer training at its facility or anywhere in the world.

Thrustmaster maintains a large inventory of spare parts at its Houston manufacturing facility as well as in strategic areas such as England, Dubai and China. Spare parts can be shipped within 24 hours to any location in the world.

 

C. Key Personnel

1. Joe R. Bekker, B.Sc.M.E President
Joe R. Bekker is the founder and President of Thrustmaster of Texas, Inc. Joe is a graduate of the University of Amsterdam in the Netherlands, holding a Bachelor of Science degree in Mechanical Engineering. He is a member of the Society of Naval Architects and Marine Engineers (SNAME) and the American Society of Naval Engineers (ASNE).

2. Owen Traylor, General Manager
Owen Traylor has over thirty-five years of experience in heavy equipment fabrication, manufacturing and plant management. Owen acts as Thrustmaster's Chief Operating Officer with all department heads reporting to him and ensures that adequate resource allocation is available to complete each project.

3. Shaw X. Dou, Ph.D., Chief Engineer
Dr. Shaw X. Dou, is a specialist in geared power transmissions and holds both a B.S. and M.S. from Jiao Tong University in Shanghai, China, and a Ph.D. fromTennessee Technological University, all in Mechanical Engineering. Shaw has been designing cyclo-palloid and rotational gear transmissions and sub-systems for marine thrusters at Thrustmaster for more than 10 years. She is a member of the American Society of Mechanical Engineers (ASME).

4. Jason D. Small, B.Sc.Mar.E, Engineering Manager
Jason Small is a graduate of Texas A&M University and holds a Bachelor of Science degree in Marine Engineering. Prior to coming to Thrustmaster, Jason conducted research in dynamic positioning control logic and served aboard ship for Kirby Inland Marine as a member of the deck department holding a U.S. Coast Guard master's license for near coastal motor vessels. Jason is responsible for the overall management of work flow through the engineering department as well as design of hydraulic and electrical power transmission systems.

5. Hee Soek Ahn, Ph.D., Senior Mechanical Design Engineer
Dr. Ahn is a specialist in computational fluid dynamics (CFD) and has a doctorate in mechanical engineering from Texas A&M University, as well as a master's and bachelor's degree in mechanical engineering from Korea University in Seoul, Korea. Prior to coming onboard Thrustmaster as a senior design engineer, Dr. Ahn, completed a post-doctorate in nuclear engineering where he conducted research on multi-phasic flow and heat transfer. Dr. Ahn previously worked as a senior research engineer for the Hyundai Motor Company's engine research division. At Thrustmaster, Dr. Ahn conducts research and development on thruster performance and other fluid dynamics projects related to marine propulsion. He is a member of the American Society of Mechanical Engineers (ASME) and the Institute of Electrical and Electronics Engineers (IEEE).

6. Sang Jin Lee, Ph.D., Mechanical Design Engineer
Dr. Lee has a doctorate in mechanical engineering from the Texas A&M University, a Master of Science in mechanical engineering from Pennsylvania State University, and both a master's and bachelor's degree in mechanical engineering from Ajou University in South Korea. Dr. Lee's expertise is in nonlinear Finite Element Modeling (FEM) for the design of mechanical components and structures as well as vibration measurement and analysis of rotating machinery. Dr. Lee has extensive experience in the design of mechanical and hydraulic power transmission systems.

7. Babu Sridharala, Ph.D., Mechanical Design Engineer
Dr. Sridharala has a doctorate in mechanical engineering from the University of Nevada, Las Vegas, where he conducted research on product optimization and Finite Element Analysis (FEA). Babu's undergraduate education was in mechanical engineering at the Bapatla Engineering College in Southern India before earning a Master of Science in Mechanical Engineering at Tennessee
Technical University. Since joining Thrustmaster, Dr. Sridharala has enhanced the expertise of the engineering department particularly in the areas of solid and 3-D modeling, shock analysis, and FEA where he has been widely published. Babu Sridharala is a member of the American Society of Mechanical Engineers (ASME), the Society for the Advancement of Materials and Process Engineering (SAMPE), and the American Institute of Aeronautics and Astronautics (AIAA).

8. Venkat Mudupu, Ph.D., Controls Design Engineer
Venkat Mudupu is a specialist in design of control systems for dynamic applications including programmable logic controllers for both marine and aerospace applications. Dr. Mudupu has a doctorate in mechanical engineering from the University of Nevada, Las Vegas, where he conducted research on feedback control, adaptive and fuzzy logic, and non-linear control systems. Dr. Mudupu is responsible for design and implementation of both analog and digital thruster control systems.

9. Yonghee Lee, M.Sc.M.E., Mechanical Design Engineer
Yonghee Lee hails from Seoul, Korea, where he earned a Bachelor of Science in machine design from Sungkyunkwan University's College of Science and Engineering before working as an engineer for Hyundai's automotive division. Mr. Lee then decided to pursue a Master of Mechanical Engineering at Texas A&M University, graduating with honors. At Thrustmaster, Mr. Lee is responsible for the design of mechanical power transmission systems including 3-D modeling of thruster components and systems.

10. Louis James (Jim) Levy, Senior Engineering Design Graphics Technician
Jim Levy has overseen the engineering design graphics department at Thrustmaster for over 12 years. Jim is a graduate of the Maryland Drafting Institute in Springfield, Virginia, and has earned various certifications in mechanical and architectural drafting as well as completing advanced training in AutoCAD, SolidWorks, Geometric Dimensioning and Tolerancing (GD&T), and the design of hydraulic fluid power systems.

11. Pamela R. Robinson, Senior Mechanical Designer
Pam Robinson comes to Thrustmaster from the aerospace and petrochemical industries where she has over 20 years of solid modeling, component, and piping design experience. Pam has a B.A. from Sul Ross State University and is a certificated instructor in CADD. Pam's previous experience in the design of aerospace components, piping and instrument diagrams (P&ID), and material assurance includes work for a NASA contractor and various petrochemical engineering firms.

12. Rabiul Alam, M.Sc.M.E. Mechanical Designer
Raiul Alum has a Master's Degree in Mechanical Engineering from Texas A&M University, a Master's Degree in Mathematics from Prairie View A&M University and a Bachelor of Science in Mechanical Engineering from Bangladesh University of Engineering and Technology. Rabiul Alam has extensive experience in 3D and 2D design of complex machinery components and assembly as well as complex hydraulic system design.

13. Michael D. Amrozowicz, M.Sc.M.E, M.Sc.N.E., M.B.A, Project Manager
As a former nuclear submarine engineering officer in the U.S. Navy, Mike Amrozowicz has an extensive educational and professional background in nuclear and marine propulsion engineering as well as extensive project and risk management in major surface combat ship procurement and construction. Mike has earned a Bachelor of Science in Electrical Engineering from the University of Florida, a Master of Mechanical Engineering, Master of Ocean Systems Management and Naval Engineering from the Massachusetts Institute of Technology, as well as a Master of Business Administration from the Collage of William and Mary. Prior to joining the project management team at Thrustmaster, Mike was a Program Support Manager and an Engineering Manager for Northrop-Grumman Shipbuilding in Newport News, Virginia. At Thrustmaster, Mike is responsible for the management of azimuthing thruster projects for main propulsion applications. Mike Amrozowicz is a member of the Project Management Institute (PMI) and the Society of Naval Architects and Marine Engineers (SNAME).

14. Karl Strauss, Project Manager/Hydraulic Systems Engineer
Karl has over 35 years experience in the mechanical and hydraulic power transmission industries, the last 20 of which have been in the marine and offshore sectors. Prior to joining Thrustmaster, he has held senior positions with Bosch-Rexroth, Hagglunds, and the Caterpillar Engine Company. Karl presently is a project manager in our engineered systems group and also acts as the resource person for special hydraulic systems design. Karl is a member of the Society of Naval Architects and Marine Engineers (SNAME) and the Canadian Institute of Marine Engineers.

15. Sam R. Moore, M.Sc.M.E, Project Manager
Sam Moore is Thrustmaster's technical project manager for azimuthing thrusters used in drill ship and semi-submersible platform applications. Sam earned a Bachelor of Science in Agricultural Engineering and Master of Science in Mechanical and Agriculture Engineering from Texas Tech University and has more than 40 years of experience in the design, manufacture, and project administration of rotating and hydraulic-powered equipment including offshore deepwater drilling and production applications. His previous experience has included design engineer, development engineer, chief engineer, vice president of engineering, vice president of manufacturing, project manager, and senior consulting engineer for various concerns involved in the design and manufacture of heavy construction equipment, non-destructive oilfield tubulars test equipment, and offshore deepwater systems.

16. Rob Watson, Project Manager
Rob Watson brings experience as a former U.S. Coast Guard Boarding Officer in Alaska and Marine Safety Team Leader at the Port of Houston. As a Professional Research Assistant at the University of Colorado, Rob designed and constructed prototype equipment and experiments for the High Energy Particle Physics department for the Superconducting Super-Collider. Rob also brings over 20 years hands-on experience in manufacturing engineering, machining, fabrication, and 3D CAD and conceptual designs for shipyards, work vessels, patrol boats and yachts. Rob currently develops mechanical animations related to equipment and thruster installations and is the project manager for the new
Thrustmaster facility.

17. James R. (Jim) Pickett, Operations Manager
Jim Pickett is the Operations Manager for Thrustmaster and is responsible for the supervision of the machining, fabrication, and assembly of our marine propulsion products. Jim Pickett has nearly 30 years of mechanical, shop operations, supervisory, and management experience in the maintenance, repair, and production of rotating and gas turbine equipment used in the chemical,
petrochemical, and power generation industries.

18. Mike Wilson, Manufacturing Engineering Manager
Mike Wilson comes to Thrustmaster with more than 30 years experience in manual and CNC machine operations, CNC programming, CAD/CAM administration, lean manufacturing, and manufacturing engineering. Mike's combination of hand's on machining and manufacturing experience plus administrative, instructional, and supervisory experience makes him an excellent
asset for managing the complex manufacturing processes used by Thrustmaster for production of its state of the art marine propulsion products. Mike Wilson is responsible for the overall supervision of the manufacturing engineering department. Mike is a member of the Society for Manufacturing Engineers.

19. Ira J. Woods, Quality Manager
With over 20 years experience in rotating equipment and over 13 years experience as a Certified Lead Auditor, Ira brings to Thrustmaster a wealth of experience. Ira has numerous certifications in Non-Destructive Testing including Level II ultrasonic as well as magnetic particle and liquid penetrant procedures. In his position as Quality Manager, Ira is responsible for maintaining day-to-day quality procedures throughout the company, supervision of the quality control inspectors, as well as monitoring strict adherence to the Thrustmaster ISO- 9001:2000 quality program.

20. David M.A. Hollaway, B.Sc.Avn.E, HSE Safety & Training Manager
Dave has more than 25 years experience in the marine and aviation industries including seven years as a Senior Applications Engineer for Thrustmaster before becoming the HSE Safety and Training Manager. Dave earned a Bachelor of Science degree in Aviation Engineering from American Technological University as well completing numerous safety and mishap prevention courses from the U.S. Army, U.S. Coast Guard, and is a graduate of the U.S. Department of Transportation Safety Institute (TSI). Dave earned the Associate in Claims (AIC) and an Associate in Risk Management (ARM) ratings from the Insurance Institute of America (IAA) as well as holding Advanced Ground Instructor (AGI) and Instrument Ground Instructor (IGI) certificates from the Federal Aviation Administration. Dave has taught technical systems and safety courses for NASA, Boeing, Bell Helicopter Textron, Continental Airlines, Lockheed-Martin Space Systems, the U.S. Coast Guard, and the Federal Aviation Administration. Dave Hollaway is a member of the Society of Naval Architects and Marine Engineers (SNAME) and American Society of Naval Engineers (ASNE).

21. Terri P. Sepulveda, Technical Documentation Specialist
Terri Sepulveda is responsible for the organization and management of technical documentation in accordance with Thrustmaster's File Data Management System (FDMS). Terri has extensive experience in complex document control systems, technical drawing revision management, project tracking, and contractual compliance.

22. Robert Cook, Materials Manager
With more than 28 years experience as both a materials and plant manager, Bob Cook is Thrustmaster's Materials Manager. Bob supervises the purchasing department was well as the warehouse and shipping and receiving departments.

23. Don Zadik, Service Manager
Don Zadik has over 32 years combined maintenance and service related experience, including 18 years in the U.S. Navy in electro-hydraulic systems as well 10 years as a senior electrician and six years as a Field Service Engineer with Thrustmaster. Don is a graduate of the Universal Technical Institute program in Automotive Technology and is in charge of managing Thrustmaster's service department as well as handling customer requests for service, repairs and rebuilds.

24. Russell Hendrix, Service Technical Advisor
Russell Hendrix is the Service Technical Advisor for Thrustmaster's field service department. Russell has over 20 years combined maintenance and service related experience, including eight years service with the U.S. Army as a heavy equipment mechanic and seven years as Field Service Engineer with Thrustmaster. He is responsible for service technical advice and assistance to Thrustmaster service technicians and for customer technical assistance on service-related technical issues.

25. Gregory S. Ault, Financial Controller
Greg Ault studied business and financial management at Texas A&M University and brings 15 years of experience to the position of Financial Controller. Greg is responsible for all company financial data, project budget tracking and reconciliation, and supervises the accounting and financial staff.

D. Current Facilities

Plant DescriptionsCurrent production facilities include nearly 90,000 square feet of manufacturing space and 20,000 square feet of office and administrative space located on a 13 acre land tract in the Northwest Industrial Complex. Overhead handling includes numerous multi-ton mobile bridge and jib cranes installed in the fabrication, machining and assembly bays to maneuver the large size of the thrusters. The facility includes both a large area for Factory Acceptance Testing as well as a 15,000 square foot multi-level stacked spare parts warehouse.

 


Thruster Assembly Bay A-1

Thruster Assembly Bay B-2

Stacked Parts Warehouse

Fabrication & Machining Bay B-1

Design and Engineering

Thrustmaster has a complete and experienced engineering staff which designs all of its thruster and control systems. More than 1,000 of the Thrustmaster propulsion thrusters are in operation all over the world.

Its customers include just about every major commercial marine operator and shipbuilder including the U.S., British, Pakistani, Portuguese, Egyptian, and Columbian navies. Commercial customers include Shell Oil, Exxon-Mobil, Tidewater Marine, Secor Marine, Baker Marine, Rigdon Marine, Keppel Marine, Global Industries, Nippon Salvage, Fukada Salvage, Damen Shipyards, Austal Ships, Cheoy Lee Shipyards, Wuchang Shipbuilding, General Dynamics’ Bath Iron Works, Vosper-Thornycraft, as well as the Venezuelan (PDVSA) and Brazilian (Petrobras) offshore oil exploration and production concerns.

State-of-the-art design tools including AutoCAD, SolidWorks, AnSys Finite Element Analysis (FEA), HydroComp, and many other engineering, computational and Computer Aided Manufacturing (CAM) systems are in use at Thrustmaster’s headquarters in Houston, including CD-adapco Computational Fluid Dynamics (CFD). Much of the engineering staff possesses advanced engineering degrees including two doctorates (Ph.D.) and several Master level (M.Sc.) engineers. Thrustmaster’s engineers come from the U.S. China, Korea, India and the Netherlands, facilitating excellent communications with customers worldwide.

 

Fabrication, Machining, Assembly & Testing

Fabrication, Machining, Assembly & Testing All Thrustmaster welders and weld procedures are certified under the guidelines set forth in the current ASME or AWS D1.1/D1.1M Structural Welding Code as well as the requirements of the classification societies rules for building and classing both steel and aluminum vessels. The company has an extensive volume of its own certified weld procedures and is capable of writing and qualifying any procedure that may be required to properly fabricate any materials the project may require. GTAW, GMAW, SMAW, and Flux Core (FCAW) procedures are fully qualified.

Machining tools include large horizontal boring mills, vertical turret lathes, manual and CNC engine lathes, as well as both vertical and horizontal CNC machining centers.




CNC and VTC Machines along with CNC Turning Centers will be included in the new Factory.

Thrustmaster’s staff of experienced assembly technicians carefully assemble all components of the thruster in accordance with a written procedure as part of the project quality plan. During the assembly procedure, quality inspection hold points are inserted to ensure that the assembled product complies with the required procedure and the quality plan. A staff of line inspectors routinely spot check all assemblies to ensure quality compliance.

 

A complete control shop designs, fabricates, and tests thruster control systems. Controls include Full-Follow-Up (FFU), Non-Follow-Up (NFU), and complete interfacing with electrical, pneumatic, or digital controls including all classes of dynamic positioning computer systems.

 

D. Future Facilities

General Description Due to long range planning for the exponential growth of its marine propulsion equipment, Thrustmaster is in the process of constructing a new manufacturing facility on a 60 acre land tract. The new facility will include a 200,000 square foot thruster factory, a separate two-story, 40,000 square foot engineering design and administrative center, and a large outdoor in-water test facility for testing of large thrusters including testing of thruster underwater mount and dismount integrity.

The future facility includes a large parts warehouse, assembly and test bay with a 40 foot crane hook height, machine shop with a 30 foot crane hook height, and a fabrication bay with a 30 foot hook height. Overhead handling facilities include a 100 ton bridge crane in the assembly & test bay extended to the thruster water test pit in addition to several 50, 30, and 15 ton bridge cranes.

Site Layout

 

4. Product Line

Tunnel Thrusters

Tunnel thrusters and bow thrusters are primarily used for docking, slow speed maneuvering, emergency steering and station keeping at zero or slow forward speed. Tunnel hrusters are installed transversely in the bow or the stern of a vessel.

Electric drive tunnel thrusters with fixed pitch propeller are available from 250 to 6,000 horsepower (180 – 5,000 kW). They are designed for variable speed electric motor input, either DC with SCR or variable speed drive control systems or AC with variable frequency drives. Most of hem are used in dynamic positioning applications. Thrusters can be supplied complete with electric motors and drives or they can be made to fit flange and shaft end of a customer supplied or shipyard supplied electric motor.

Tunnel thrusters for direct engine drive are available in the range of 250 to 6,000 horsepower (180 – 5,000 kW). The engine must be provided with a marine gear with a reduction ratio to match the input speed of the thruster. A cardan shaft connects between the output shaft of the marine gear and the input shaft of the thruster.

Thrustmaster offers a great line of hydraulic tunnel thrusters from 35 to 2,000 horsepower (26 – 1,500 kW). They are used all over the world and many of them in dynamic positioning applications. Many models have ABS Type Approval.

 

 

 

 

Azimuthing Thrusters

Azimuth thrusters are for main propulsion and dynamic positioning of displacement vessels and offshore facilities. They are available in a wide range of input power and speeds. They replace conventional propulsion and rudder steering systems to perform both the propulsion and steering functions. Azimuth thrusters are used when enhanced maneuverability is required in applications such as dynamic positioning, ship escort and ship docking services.

Thrustmaster azimuthing thrusters are available for vertical (L) or horizontal (Z) prime mover input and use fixed pitch propellers in open wheel configuration or with nozzles. They may be optimized for vessel speed or for maximum bollard thrust. Azimuthing thrusters are available from 250 to 8,000 horsepower (180 – 6,000 kW) with a wide selection of reduction ratios and propeller/nozzle diameters to suit the application requirements. They are available with integral wet hydraulic or dry air actuated clutch, in top pull-out, underwater bottom-mount or weld-in configuration.

Hydraulic L-Drive thrusters are thru-hull azimuth thrusters using Thrustmaster's hydraulic podded propeller drives. These thrusters are available in a range from 75 to 2,000 horsepower (56 – 1,500 kW) with either open propeller or with nozzle. The hydraulic power system is normally supplied by Thrustmaster and may be configured for the hydraulic pump driven by a customer furnished diesel engine, which may be placed at any convenient location in the vessel. Hydraulic piping or hoses connect between the hydraulic pump and the thruster. The hydraulic drive provides fully proportional propeller speed control and is very forgiving when hitting obstacles in brown water applications.

Two 1,000 SHP Thrusters Under Load Test

Retractable Thrusters

Thrustmaster retractable thrusters are thru-hull azimuthing thrusters using fixed pitch propellers at variable speed. Most commonly, they use ducted propellers and are used for dynamic positioning or slow speed course tracking applications. They are available with electric drive from 250 to 3,000 horsepower (180 – 2,300 kW) or with hydraulic drive from 75 to 2,000 horsepower (56 – 1,500 kW).

Thrustmaster electric retractable thrusters are fixed pitch propeller thru-hull azimuth thrusters capable of retracting completely into the hull. They are configured for vertical variable speed electric motor input. Sizes range from 250 to 3,000 horsepower (180 – 2,300 kW) with a wide selection of reduction ratios and propeller/nozzle diameters to suit the application requirements. These thrusters are normally supplied complete with electric motors and variable frequency drives, but they can also be made to fit flange and shaft end of a customer supplied or shipyard supplied electric motor. The motor travels up and down with the thruster, so the drive line is never disconnected.

 

Thrustmaster hydraulic retractable thrusters are thru-hull azimuth thrusters using Thrustmaster’s exclusive hydraulic podded propeller drives. They are available in a range from 75 to 2,000 horsepower (56 – 1,500 kW) with either open propeller or with nozzle. Thrusters can be supplied in aluminum or in steel construction, depending on vessel hull material. The hydraulic power system is normally supplied by Thrustmaster and may be configured for the hydraulic pump driven by customer furnished diesel engine or other prime mover, which may be placed at any convenient location in the vessel. Hydraulic piping or hoses connect between the hydraulic pump and the thruster. The hydraulic drive provides fully proportional propeller speed control while the engine is running at constant speed.

Thrustmaster’s retractable thrusters are also available as combination thrusters, functioning as tunnel thruster in the retracted position and freely azimuthing in the lowered position. Compact units are available for vessels with limited hull depth. A hull fairing piece is normally attached to the bottom of the thruster to reduce drag when the thruster is stowed.

 

Deck-Mounted Propulsion Units

Propulsion units are self-contained thruster packages for main propulsion and positioning of barges, platforms and river craft. They are available either with direct engine drive, using geared power transmissions or with hydraulic drive. The hydraulic drive is especially suited for shallow, brown water applications while the geared units are primarily used in deeper, blue water.

Direct engine driven propulsion units are available from 150 to 3,000 horsepower (112 – 2,300 kW) either with open propeller or with nozzle. They are engineered on application and are available with a wide variety of engine, gear reduction ratio, propeller diameter and stem length. These propulsion units are usually installed on deck, often in slots or notches in the transom.

Hydraulic Propulsion Units are available from 35 to 2,000 horsepower (26 – 1,500 kW) either with open propeller or with nozzle. The hydraulic drive provides fully proportional propeller speed control in forward and reverse while the engine runs at constant speed. Many options are available, including hydraulic kick-up of the outdrive, hydraulic propeller depth adjustment, remote control panels, choice of engines, etc. The WORKMASTER™ style provides for 180 degrees steering and is for general propulsion applications. The THRUSTMASTER™ style is freely azimuthing with endless 360 degrees steering and is used for double-ended river ferries, dynamic positioning and similar applications.

All units can be configured as deck-mounted packaged units, deck-mounted mini-skid units or transom-mounted units. The mini-skid and transom-mount styles allow remote mounting of the engine, either above or below deck at any convenient space, while the packaged units include the engine on the skid.

Transom-mounted units are ideal for applications where sufficient freeboard is available. They can be welded to the transom or sides of vessels, barges or platforms. Frequent immersion from wave action is no problem. The engine and hydraulic power unit may be installed on deck or in an engine room at any convenient location. A single engine may power multiple transom-mounted thrusters.

 

Portable Dynamic Positioning (PDPS)

Thrustmaster of Texas has developed a portable dynamic positioning system consisting of modular, deck mounted, azimuthing thrusters with separate hydraulic power units and a DP control console. The whole system can be installed dockside, takes a minimum of deck space and does not require any permanent vessel modifications. Installation can be completed within days.

The system normally consists of four or more thrusters, four or more hydraulic power units, one (1) central DP console and the interconnecting hydraulic hoses between thrusters and power units, and electrical control cables between power units and console. Standard thruster sizes are 250, 500, 1,000, 1,500, and 2,000 horsepower (180 – 1,500 kW). Using multiple units, systems ranging from 500 horsepower (2 x 250 HP) up to 24,000 horsepower (12 x 2,000 HP) may be configured.

The portable thrusters are mounted on deck using a minimum amount of deck space. They use direct hydraulic drive to the propeller. The variable speed hydrostatic drive motor is in the lower foot of the thruster directly in line with the propeller shaft. This direct hydraulic drive eliminates the need for right angle gear transmissions and drive shafts used on other thrusters. Hydraulic hoses run from the deck mounted upper thruster assembly down to the propulsion motor in the lower foot of the thruster. It allows mounting on deck without intermediate stem support.

 

Each thruster is powered by its own hydraulic power unit. These power units are enclosed marine type hydrostatic transmission units using a radiator cooled Caterpillar diesel engine as prime mover. Some of these units use a standard 20 foot or 40 foot ISO container as enclosure. They may be installed at any location based on deck space availability or optimum weight distribution. The units are complete with fuel day tank, independent battery powered electric start and control system with automatic alarms and shutdown and are provided with critical grade muffler and noise attenuating equipment. These power packs produce the hydraulic power for the propeller drive system as well as hydraulics for steering and auxiliary functions.

6. Quality Management

Quality Policy Statement
Thrustmaster of Texas, Inc. is committed to producing products and services at a level of quality and reliability equal to or better than its major competitors.

OBJECTIVES

Maintain a quality system in full compliance with ANSI/ISO/ASQC Q9001.

Provide products and services that meet the needs of our customers.

Reduce the occurrence of warranty claims.

Improve on-time delivery of new unit orders.


Management will continually assess progress towards these objectives and pursue opportunities for improvement. Customer satisfaction is achieved by providing quality products, on time, and backed up by exceptional service.

Quality Management System (QMS)
Thrustmaster has developed and implemented a Quality Management System (QMS) to enable the company to operate with increased effectiveness, consistency and customer satisfaction. The system is certified by the American Bureau of Shipping (ABS) Quality Evaluations branch to be in compliance with ISO-9001:2000 and covers the design and manufacture of all company products and operations at its Houston, Texas, facility.

Thrustmaster company management continues to demonstrate its commitment to the quality management system through daily active participation, communication, management reviews, enforcement of the quality policy and by ensuring the availability of required resources. Management ensures that the quality policy is understood, implemented, and maintained at all levels of the organization through an employee continuous training program as well as quantified improvement and operational objectives.

Thrustmaster utilizes a team approach with its customers through routine visits, joint planning and implementation meetings, industry trade show and professional society participation, and customer audits of the company’s facilities.

7. Health, Safety & Environmental (HSE)

HSE Policy Statement
The management philosophy for Thrustmaster of Texas, Inc. incorporates health, safety and environmental (HSE) excellence as a core corporate value. Along with its customers, contractors and suppliers, Thrustmaster shares the vision that it can perform its operations in such a way that no one gets hurt and nothing gets harmed or adversely impacted. Therefore, it is the policy of Thrustmaster to:

    • Comply with all relevant HSE legislation, regulations and other requirements;
    • Ensure that systems are developed and implemented to identify, assess,
      monitor, periodically review and control HSE impacts related to all operations and
      business activities;
    • Set HSE objectives and targets, and achieve superior performance (i.e., pollution
      prevention, hazard elimination, no accidents or mishaps) through the utilization of
      a continuous improvement process incorporating Six Sigma methodology;
    • Provide necessary training and education to enable employees to understand
      and perform their roles and responsibilities involved with their job functions; and
    • Implement mechanisms to communicate with and obtain input from employees,
      customers, contractors and other interested parties to the HSE Management
      System.


    This statement of policy is the foundation that supports the entire HSE Management
    System. It establishes Thrustmaster’s management philosophy with regard to the HSE
    values, as well as a shared vision between its customers, contractors and suppliers.

HSE Management System
The HSE Policy Manual describes the HSE Management System responsibilities of the Thrustmaster organization, and control features necessary for achieving its HSE vision. Compliance with this manual is consistently applied at all Thrustmaster facilities and operations, installations, dock and sea trials. Each employee identified with responsibilities in the HSE Management System is responsible for implementing the requirements specifically assigned, and visibly demonstrating their commitment to the HSE process through their actions while performing their work duties.

Thrustmaster has invested heavily in educating and promoting effective HSE practices among its employees. Courses in safety management and leadership, first aid, cardio pulmonary resuscitation (CPR) and automated external defibrillator (AED) certification, fire prevention, hazardous material and waste handling, HSE workshops, emergency preparedness drills and educational literature are just a few examples.

Planning is an integral component within the HSE Management System, and allows Thrustmaster to assess needs, set targets and lay the groundwork toward compliance with its HSE Policy Statement and objectives. Planning is an ongoing activity, which requires the identification of hazards, risks, controls and legal requirements, as well as establishing long-term goals.

HSE Hazard Identification, Risk Management & Control
This process involves a cross-functional HSE Committee made up of representatives from various levels of the organization, including management, operations and other support and staff functions, utilizing established management system tools to identify the hazards and risks associated with the various activities performed at each location. Each activity or operation is carefully examined using a risk matrix and ranked to establish risk priorities. This process ensures accurate identification and implementation of necessary control measures before any work begins.

Identification of Regulatory Requirements
Relevant regulatory or legal aspects and other requirements (customer requests, for example) are considered during the HSE planning process. This ensures that each project has access to, and evaluates, any laws, regulations and other requirements that affect HSE issues relating to Thrustmaster’s activities, products and services.

HSE Objectives and Goals
Objectives and goals are initiatives designed to minimize hazards and risks within specific activities that have been identified through the assessment process. An objective is a general goal and may carry with it any number of measurable specific goals. Objectives and goals may be initiated at business unit level and are managed by the HSE Committee.

Management Review
Effectiveness is evaluated at least annually at the management review and is intended to provide a forum for open discussion and improvement of the Thrustmaster HSE Management System.

8. Project References

The following section provides a short selected synopsis of Thrustmaster’s recent project experience.

Y020300 P&R Water Taxi

Provided six (6) Model TH-2000M azimuthing thrusters in the Z-drive
configuration for fleet improvement of Azimuthing Stern Drive (ASD) escort tugs
for escorting U.S. Navy surface ships and submarines into Naval Base Pearl
Harbor. Classification of thrusters per ABS Rules.

Y040239 Wuchang Shipyard

Provided four (4) Model TH-1500MZ azimuthing thrusters in the Z-drive
configuration for a harbor tug fleet improvement program. Classification of
thrusters per CCS Rules.

Y040350 U.S. Navy – GDBIW – Austal Ships

Providing up to 20 Model TH-850RN retractable azimuthing thrusters for
installation in the U.S. Navy Littoral Combat Ship (LCS) fleet improvement
program. LCS vessels are under construction at the General Dynamics Bath Iron
Works (GDBIW) facility in Maine and at the Austal Ships U.S. facility in Mobile,
Alabama. Project required complex design and shock testing of thrusters for
combat survival. Received the Subcontractor of the Year award for project
management. Classification of thrusters per ABS Rules.

Y040357 Wuchang Shipyard

Provided two (2) additional Model TH-1500MZ azimuthing thrusters in the Z-drive
configuration for harbor tug fleet improvement. Classification of thrusters per
CCS Rules.

Y060079 SIMA-PERU

Provided two (2) TH-1500MZ azimuthing thrusters in the Z-drive configuration for
harbor tug fleet improvement. Classification of Thrusters per ABS Rules.

Y060084 Shell Offshore, Inc.

Provided four (4) Model OD-2000N and four (4) containerized diesel-hydraulic
power units (HPU) rated for 2,000 HP (1,500 kW) for conversion of a semi-
submersible drilling platform to dynamic positioning. Classification of thrusters
per DNV Rules with Type Approval Certificate.

Y060139 PMS Offshore

Provided four (4) Model OD-1500N and four (4) containerized diesel-hydraulic
power units (HPU) rated at 1,500 HP (1,200 kW) for conversion of an offshore
crane barge for dynamic positioning. Classification of thrusters per LRS Rules.

Y060215 Petrobras


Provided six (6) Model OD-2000N and six (6) containerized diesel-hydraulic
power units (HPU) rated at 2,000 HP (1,500 kW) for conversion of an offshore
pipelay barge to dynamic positioning. Classification of thrusters per ABS Rules.

Y060280 PT Masa



Provided three (3) Model OD-1000N and three (3) containerized diesel-hydraulic
power units (HPU) rated at 1,000 HP (745 kW) for conversion of an offshore
work-over barge to dynamic positioning. Classification of thrusters per BV Rules.


Y060355 Crossmar

Provided four (4) Model OD-1000N and four (4) containerized diesel-hydraulic
power units (HPU) rated at 1,000 HP (745 kW) for conversion of an offshore
construction support barge to dynamic positioning. Classification of thrusters per
ABS Rules.

Y060432 Helix Energy Solutions

Provided two (2) Model OD-2000N and two (2) containerized diesel-hydraulic
power units (HPU) rated at 2,000 HP (1500 kW) for conversion of a Floating
Production Vessel (FPV) to dynamic positioning. Classification of thrusters per
LRS Rules.

Y060437 Dubai Shipbuilding

Provided two (2) Model OD-1000N and two (2) containerized diesel-hydraulic
power units (HPU) rated at 1,000 HP (745 kW) for conversion of an offshore
crane barge to dynamic positioning. Classification of thrusters per LRS Rules.

Y060455 Frontier Drilling

Provided two (2) Model TH-2000ML electric-driven L-drive azimuthing thrusters
rated for 2,000 HP (1,500 kW) for conversion of an offshore drill ship to dynamic
positioning. Classification of thrusters per LRS Rules.

Y070196 Helix Energy Solutions

Provided two (2) Model 66TT900 transverse tunnel thrusters rated at 900
horsepower (670 kW) for conversion of a mobile offshore drilling unit (MODU) to
dynamic positioning. Classification of thrusters per ABS Rules.

Y070020 Frontier Drilling

Providing two shipsets of six (6) Model TH-6000ML electric-driven L-drive
azimuthing thrusters rated for 6,000 HP (4,475 kW) for dynamically positioned
offshore drill ships. Classification of thrusters per DNV Ice Class Rules.

Y070275 Confidential Contract

Providing 40 Model TH-5000ML electric driven L-drive azimuthing thrusters rated
at 5,000 HP (3,730 kW) for dynamic positioning of semi-submersibles.
Classification of thrusters as determined by customer.

Y070281 Dubai Shipbuilding

Providing four (4) Model TH-2500MZ engine-driven azimuthing thrusters in the Z-
drive configuration rated for 2,500 HP (1,865 kW) and four (4) Model 56TT600
transverse tunnel thruster rated for 600 HP (445 kW) for new-build offshore
anchor handling tug and supply (AHTS) vessel. Classification of thrusters per BV
Rules.

Y070384 Landstrong Group, Inc.

Providing two ship sets (4) Model TH-2000MZ engine-driven azimuthing
thrusters in the Z-drive configuration rated for 2,000 HP (1,500 kW) for
new-build ASD tugs. Classification per CCS rules.

Y070410 Davie Quebec, Inc.

Providing two ship sets (10) Model TH-2500MZ azimuthing thrusters in the
Z-drive configuration rated for 2,500 HP (1,865 kW) for two
accommodation barges. Classification per DNV rules.

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