STATEMENT OF QUALIFICATIONS
FOR THE MANUFACTURE OF COMMERCIAL MARINE PROPULSION EQUIPMENT
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- THRUSTMASTER OF TEXAS, INC.
- 6900 THRUSTMASTER DRIVE
- HOUSTON, TEXAS 77041
- VOICE - 713.937.6295 FACSIMILE
- 713.937.7962
- www.thrustmastertexas.com
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MESSAGE FROM THE PRESIDENT
OF THRUSTMASTER OF TEXAS, INC.
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 Thank
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-9001:2008 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
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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 deck-mounted
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-9001:2008 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.
Production facilities include a new 200,000 square foot (18,580
m2) state-of-the art thruster manufacturing facility
and 40,000 square feet of (3,700 m2) design and administrative
space located on a 60 acre (242,800 m2) tract northwest
Houston, Texas. In the last quarter of 2010, Thrustmaster will
start construction of its new, 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 250.
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.
SECTION 1
GENERAL HISTORY
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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 a new 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 2008, Thrustmaster upgraded
its ISO quality system to the ISO-9001:2008 standard. ABS issued
a Certificate of Manufacturing Assessment Certificate and type
approval certificates for Thrustmaster’s standard tunnel
thrusters.
In 2009, Thrustmaster moved to its new expanded facility to
support the increase in sales which now exceed USD $100-million
annually. 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.
In 2010 Thrustmaster increased offerings of Z and L drives
and diesel tunnel thrusters to include up to 10,750hp (8.0MW).
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A. 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.
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B. 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:
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.
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.
C. 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.
SECTION 3
ORGANIZATION & CAPABILITIES
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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 Vice President of Engineering
who supervises all engineering personnel and reports to the General
Manager. The VP of Engineering 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 VP of Engineering is assisted
by a number of Engineering Managers and Lead Design Engineers.
B. TECHNICAL CAPABILITIES
1. 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 management experience
is ready to serve the customer to ensure quality design and timely
delivery.
2. Integrated Supply, Engineering and Support
Through its state-of-the art engineering and manufacturing
capabilities, Thrustmaster can offer complete integrated dynamic
positioning, vessel automation, propulsion, and electrical power
generation and distribution system as well as project engineering
and management services.
The dynamic positioning and automation systems, propulsion,
electrical power generation, distribution package, including
interface engineering during vessel design and construction,
technical support for installation and commissioning, is provided
by a very experienced team of engineers.
We have a central design team coordinating the systems design
and integration before the system is constructed and placed into
service. Difficulties with regard to systems integration that
are typical to shipyard construction of semi-submersible and
ship-type drilling vessels are effectively mitigated on the front
end and not during startup and sea trials.
The single purpose is to provide and support a fully integrated
DP equipment package for mobile offshore drilling units so as
to reduce and simplify the shipyard engineering and procurement
efforts, thereby reducing cost and time required for building
and commissioning the vessels.
Thrustmaster may have single-point responsibility for integration
of all supplied subsystems and interface between the shipyard,
marine classification society, vessel designer, and all third-party
equipment within the scope of supply.
3. Systems 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® and COSMOS® Finite
Element Analysis (FEA), Magmasoft® casting simulation,
STAR-CMM+® computational fluid dynamics, and HydroComp
NavCad® software.
Fabrication & Machining
Fabrication facilities use computer controlled high pressure
waterjet, 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.
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.
4. Quality Assurance & Control (QA/QC)
Thrustmaster is certified to ISO-9001:2008 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 Manager, Quality Assurance Manager, and
a Quality Control Manager and a highly experienced team of quality
control line inspectors 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.
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.
A dedicated staff of test engineers conducts Factory Acceptance
Tests (FAT) on all systems, subsystems, hardware and software
to ensure that the thruster conforms to its design specifications
and meets all requirements for functionality.
5. 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
in accordance with ISO-18001 and ISO-14001.
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 Safety
Management System (SMS) and provide employee training. The HSE
Manager is assisted by an HSE Coordinator and number of departmental
safety inspectors as well as an organized HSE committee.
6. 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
ERP 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.
7. 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.
8. 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. CURRENT FACILITIES
1. Plant Description
 Production
facilities include a new 200,000 square foot (18,580 m2)
state-of-the art thruster manufacturing facility and 40,000 square
feet (3,700 m2) of design and administrative space
located on a 60 acre (242,800 m2) tract northwest
Houston, Texas.
The facility is divided into bays for fabrication, machining,
and assembly and incorporates a 12,800 square foot (1,200 m2)
multi-level stacked spare parts warehouse. The plant layout incorporates
Lean and cell manufacturing techniques. The facility is completely
climate controlled by a chill-water plant to ensure optimum productivity
and reduce component degradation due to environmental exposure.
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6900 Thrustmaster Drive, Houston, Texas 77041 U.S.A.
Overhead handling includes a 100 ton bridge crane, two 50
ton bridge cranes, and several 30 and 15 ton bridge cranes as
well as jib cranes installed throughout the facility to maneuver
the large size of the thrusters.
In the last quarter of 2010, Thrustmaster will start construction
of its new, large outdoor in-water test facility for testing
of large thrusters including the testing of thruster underwater
mount and dismount integrity.
- Thruster Assembly Bay A
Machining Bay A
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- Thruster Assembly Bay A-1 Thruster
Assembly Bay B-2
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- Stacked Parts Warehouse Thruster
Assembly Bay A-1
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2. 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, Seacor 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 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 several doctorates (Ph.D.) and 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.
3. 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.
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Thrustmaster’s staff of experienced
assembly technicians carefully assembles 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 spots checks all assemblies
to ensure quality compliance.
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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.
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A. 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 thrusters 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 10,750 horsepower (180 kW – 8.0
MW). 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 them 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 10,750 horsepower (180 kW – 8.0 MW). 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.
B. 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 10,750 horsepower (180 kW
– 8.0 MW) 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.
C. 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 10,750 horsepower (180 kW – 8.0
MW) 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 10,750 horsepower
(180 kW – 8.0 MW) 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.
D. 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.
E. PORTABLE DYNAMIC POSITIONING SYSTEMS (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.
Installtion 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.
SECTION 5
FINANCIAL PERFORMANCE
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A. FINANCIAL PERFORMANCE
Thrustmaster of Texas, Inc. is a for-profit, closely-held
IRS Subchapter S corporation domiciled in the State of Texas.
Over the last five years, Thrustmaster has grown from USD
$15-million to almost USD $100-million in annual revenue with
an order backlog well in excess of USD $150-million.
Current financial performance projections predict that annual
revenues will exceed USD $200-million by 2012.
B. FINANCING & INSURANCE
Thrustmaster has adequate cash reserves and in-place lines
of credit adequate to handle any anticipated or unanticipated
cash flow demands for large projects.
Thrustmaster maintains comprehensive package of risk insurance
including general liability, product liability, business personal
property, and Longshoreman’s and Harborworker’s marine
coverage.
SECTION 6
QUALITY MANAGEMENT
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A. 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.
B. 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-9001:2008 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.
SECTION 7
HEALTH, SAFETY & ENVIRONMENTAL
(HSE)
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A. 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
in accordance with ISO-18001 and ISO-14001;
- 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.
B. 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.
APPENDIX A
ORGANIZATIONAL CHART
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Click for larger view
APPENDIX B
ISO-9001:2008 CERTIFICATE
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APPENDIX C
MAJOR EQUIPMENT LIST
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| . |
MAJOR EQUIPMENT
LIST |
. |
| . |
CNC Machining |
. |
| Quantity |
Nomenclature |
Capacity |
| 1 |
Turnmaster HNC-M Turning Center |
75-In x 14-Ft |
| 1 |
MAG Giddings and Lewis FT-3500 Horizontal
Boring Mill – Floor Unit |
13-Ft x 10-Ft |
| 1 |
MAG Giddings and Lewis VTC-3500 Vertical
Turning Center |
11-Ft x 12-Ft |
| 1 |
Kuraki KBT-13AE CNC Horizontal Boring
Mill |
5-Ft x 6 Ft |
| 1 |
Daewoo Puma 700L CNC Horizontal Machining
Center |
36-Inch |
| 1 |
Daewoo DHM-800 CNC Vertical Machining
Center |
30-Inch |
| 1 |
Daewoo Puma 12L-C CNC Horizontal
Machining Center |
20-Inch |
| 1 |
Daewoo Mynx-500 CNC Vertical Machining
Center |
15-Inch |
| . |
Manual Machining |
. |
| 1 |
Vanguard TXP6113/2 Horizontal Boring
Mill |
36-Inch |
| 1 |
Vanguard CW6280C Horizontal Engine
Lathe |
30-Inch |
| 1 |
Vanguard CA6250C Horizontal Engine
Lathe |
20-Inch |
| 1 |
Bullard ‘Cut-Master’
Vertical Turret Lathe |
64-Inch |
| 1 |
Niles HD-6 Heavy Duty Horizontal
Boring Mill |
66-Inch |
| 1 |
H.E.S. 24 Horizontal Engine Lathe |
24-Inch |
| 1 |
Lodge & Shipley Horizontal Engine
Lathe |
5-Inch |
| 1 |
SuperMill Model J Horizontal Boring
Mill |
4-Inch |
| 1 |
Kuraki KBT-1003 Horizontal Boring
Mill |
4-Inch |
| 1 |
American ‘Hole-Master’
Vertical Drill Press |
7-Inch |
| 1 |
Wells-Index Manual Vertical Boring
Mill |
2-Inch |
| . |
Fabrication |
. |
| 1 |
Vanguard H-460HA CNC Band Saw |
20-Inch |
| 1 |
Flow Mach 3 Dynamic CNC Waterjet
Cutting System |
78 x 120-Inch |
| 1 |
Linatrol Optical Tracing Plasma Plate
Burner Table |
96 x 240-Inch |
| 1 |
Kioke-Anderson PLP-2500 CNC Plasma
Plate Burner Table |
120 x 240-Inch |
| 15 |
Miller AC Welding Machines (GTAW,
GMAW, SMAC, FCAW, SubArc) |
|
| 1 |
Two-Axis Welding Manipulator |
30 Ton |
| 2 |
Two-Axis Welding Manipulator |
5.0 Ton |
| 1 |
Two-Axis Welding Manipulator |
2.5 Ton |
| . |
Overhead
Handling |
. |
| 1 |
Overhead Bridge Crane |
100 Ton |
| 2 |
Overhead Bridge Crane |
50 Ton |
| 2 |
Overhead Bridge Crane |
30 Ton |
| 3 |
Overhead Bridge Crane |
15 Ton |
| 1 |
Overhead Bridge Crane |
10 Ton |
| . |
Material
Handling Equipment |
. |
| 1 |
Mobile Jib Crane |
30-Ton |
| 1 |
Mobile Forklift |
40,000 lbm |
| 1 |
Mobile Forklift |
25,000 lbm |
| 1 |
Mobile Forklift |
8,000 lbm |
| 5 |
Mobile Forklift |
5,000 lbm |
| . |
Assembly |
. |
| 1 |
SKF TIH 1000E Induction Heater |
6,100 lbm |
| 2 |
SKF TIH 220m Induction Heater |
660 lbm |
|