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Berg Propulsion CPP Control System Repair with DNV Class Approval — MV SWAMI, Swansea
In July 2024, Ashmit Engineering was engaged by the marine agent for MV SWAMI — a 90-metre general cargo vessel owned by Misje Rederi AS — to diagnose and repair a fault in the Berg Propulsion ECR3000 Controllable Pitch Propeller control system whilst the vessel was berthed at Swansea Harbour.
The fault was preventing reliable pitch control from the bridge station. With the vessel scheduled to depart for Limerick, time was critical. Ashmit Engineering was required not only to diagnose and repair the CPP system, but to coordinate with DNV Senior FIS Surveyor Mohsen Nateghi for witness testing and class approval before the vessel could sail.
This case study demonstrates Ashmit Engineering's capability in marine CPP control system repair, multi-vendor coordination, and acting as technical representative to class societies — a complete end-to-end service from fault diagnosis to vessel departure clearance.
Project Overview — MV SWAMI, Swansea
- Vessel
- MV SWAMI (IMO 9100126, Call Sign C6WF8)
- Flag / Port
- Bahamas / Nassau
- Owner
- Misje Rederi AS (Shipowners & Shipbrokers)
- Location
- Swansea Harbour, Wales, UK
- System
- Berg Propulsion ECR3000 CPP Control System
- CPP Rating
- 2500 hp — Bow Thruster 240 kW (326 hp)
- Vessel Dimensions
- LOA 90.46 m / Beam 13.20 m / DWT 4304 t
- Scope
- CPP fault diagnosis, potentiometer replacement, DNV witness testing, class approval
- Class Authority
- DNV — Senior FIS Surveyor, Region West Europe
- Date
- 19–20 July 2024
Site Photography — MV SWAMI, Swansea Harbour
MV SWAMI bridge console — Berg Propulsion CPP panel and Wartsila Diesel instruments
The Challenge
MV SWAMI is fitted with a Berg Propulsion ECR3000 CPP control system and a 2500 hp controllable pitch propeller, supplemented by a 240 kW bow thruster. The vessel was experiencing unreliable pitch position feedback, with the pitch lever not correctly transmitting commanded positions to the ECR control system. The system was falling back to engine room manual control during manoeuvreing — a condition that is operationally limiting and notifiable to the class society.
Hydraulic pitch tests (Half Ahead, Full Astern) conducted before Ashmit's arrival had shown CPP operating in some modes, but bridge pitch control was unreliable. The pitch feedback potentiometers — which provide the ECR with continuous position data from the lever and from the CPP servo — were suspected as the root cause.
Critically, the vessel had a departure deadline. DNV had been notified of the system fault, and a witness test and class approval were required before the vessel could legally depart Swansea. Ashmit Engineering needed to complete the full repair cycle — diagnosis, parts sourcing, replacement, calibration, and surveyor sign-off — within a single port call.
Technical Solution — Step by Step
1
On-Board Arrival and System Inspection — 19 July 2024
Ashmit Engineering arrived on board MV SWAMI at Swansea Harbour on 19 July 2024 and met with the Captain, Chief Engineer, and Second Officer. A full walkthrough of the Berg Propulsion ECR3000 system was conducted across all control stations: bridge, engine room (manual pitch control panel), and the ECR control cabinet. The pitch lever housings on the bridge and wing stations were opened and the feedback potentiometers inspected. Resistance measurements confirmed significant wear and drift in the pitch lever feedback sensors — consistent with moisture ingress and long-term corrosion in the exposed bridge environment.
2
Pitch Feedback Potentiometer Diagnosis and Identification
The Berg ECR3000 uses precision rotary potentiometers to sense the angular position of CPP control levers. Each potentiometer outputs a voltage proportional to lever angle, which the ECR compares against the actual CPP servo position. When the potentiometer resistance drifts outside tolerance — caused by worn carbon tracks or corroded wiper contacts — the ECR detects a mismatch and either generates a position error alarm or defaults to a fallback control mode. Ashmit Engineering confirmed the same failure mode seen previously on other Berg-equipped vessels: worn potentiometers causing unreliable pitch position feedback. The Berg ECR3000 CPU control board was also inspected for any secondary faults — no board-level damage was found.
3
Parts Sourcing and Novotechnik Potentiometer Replacement
Replacement Novotechnik precision potentiometers — OEM-equivalent components proven in Berg ECR3000 applications — were sourced and delivered to the vessel. The worn potentiometers were removed from the pitch lever housings. Replacement units were fitted, wired to the original terminal configuration, and secured. Zero-position calibration was then performed: with the CPP physically confirmed at zero pitch via the piston movement gauge on the servo housing, the potentiometer electrical zero was set to match — eliminating any residual offset between commanded and actual pitch position. The pitch adjuster and pitch indicator on both bridge and engine room stations were verified against the servo position.
4
Full System Test — All Control Stations Verified
Following replacement and calibration, a full functional test was carried out across all Berg Propulsion control stations. Bridge pitch control (main and backup levers), engine room manual pitch control, and the Back Up Pitch Control panel were each verified for correct pitch response, correct transfer between stations, and absence of position error alarms. The Constant RPM control mode was confirmed operational. Pitch Feedback table measurements were recorded across 13 positions from Full Astern to Full Ahead, confirming that pitch position accuracy, mechanical, and electrical readings were all within tolerance and that the CPP hydraulics responded correctly at all test points.
5
DNV Witness Testing and Class Approval — 20 July 2024
With the repair complete, Ashmit Engineering coordinated witness testing with DNV Senior FIS Surveyor Mohsen Nateghi. The surveyor was presented with the full pitch feedback test results and conducted independent verification of the CPP control system operation. All tests were passed. The surveyor confirmed class approval, clearing MV SWAMI for departure. Ashmit Engineering remained on board until the vessel was ready to sail, ensuring all documentation was complete for the shipowner, Misje Rederi AS.
Master Statement — Misje Rederi AS / MV SWAMI
“During maneuvering in Swansea Harbor and present sea passage — we have no remarks regarding the working of CPP after repair. CPP worked properly.”
— Master V. Tarasov, MV SWAMI (C6WF8), North Atlantic Ocean, South Coast of Ireland, 21 July 2024
Outcome
✅
CPP Fully Restored
Berg Propulsion ECR3000 CPP control restored to full operational status across all control stations — bridge, engine room, and backup panel.
🏛️
DNV Class Approval Obtained
Witness testing completed and class approval granted by DNV Senior FIS Surveyor. Vessel cleared for departure from Swansea Harbour.
🚢
Vessel Departed On Schedule
MV SWAMI sailed from Swansea at 17:50 on 20 July 2024. The Master confirmed CPP worked properly during manoeuvreing and full sea passage to Limerick.
📋
Full Documentation Package
Pitch feedback test tables, service report, and class approval documentation provided to Misje Rederi AS and filed for their records.
Related Marine Engineering Services
Vessel in Port? CPP Fault or Class Survey Deadline?
Ashmit Engineering engineers are available 24/7 for marine CPP emergencies across UK ports. We coordinate directly with DNV, BV, Lloyd's, and other class surveyors.
Frequently Asked Questions
- Do you work in Swansea and South Wales?
- Yes. Ashmit Engineering engineers travel to ports across Wales and the South West of England including Swansea, Cardiff, Newport, and Bristol. We can typically board a vessel within 48 hours of enquiry — and same-day for genuine emergencies. We also work internationally.
- Can you coordinate with DNV and other class surveyors?
- Yes — this is a core part of our marine service. We act as the technical representative between the shipowner or marine agent and the class society (DNV, Bureau Veritas, Lloyd's Register, ABS). We prepare the vessel for witness testing, attend the survey alongside the surveyor, and ensure all documentation is in order for class approval. On MV SWAMI, we coordinated directly with DNV Senior FIS Surveyor Mohsen Nateghi for dock departure clearance.
- What is a DNV FIS Surveyor and why do they attend CPP repairs?
- A DNV FIS (Fleet in Service) Surveyor monitors the operational condition of classed vessels between dry-dock surveys. If a safety-critical system such as the main propulsion CPP control is repaired in port, the surveyor may attend witness testing to verify the repair before authorising the vessel to continue trading. Ashmit Engineering can prepare your vessel for this process and liaise with the surveyor on your behalf.
- What is the Berg ECR3000 CPP control system?
- The Berg ECR3000 is a proprietary Controllable Pitch Propeller control system manufactured by Berg Propulsion. It manages pitch position commands from the bridge and engine room, processes feedback from potentiometer sensors, and drives the hydraulic servo system that physically changes blade angle. Faults typically manifest as pitch position errors, lever mismatch alarms, or loss of pitch control from one station. Ashmit Engineering has direct hands-on experience diagnosing and repairing ECR3000 systems.
- What CPP system brands do you support beyond Berg Propulsion?
- We support all major CPP manufacturers including KaMeWa (Wartsila), MAN Alpha, Voith Schneider, Schottel, Brunvoll, ZF Marine, Nakashima, Northrop Grumman Sperry Marine, and Rolls-Royce (formerly Kamewa). We also support associated hydraulic power units and electronic control systems from Rexroth, Parker Hannifin, and Moog.
- How quickly can you respond to a CPP fault in a UK port?
- For vessels in UK ports, we aim to have an engineer on board within 24–48 hours of your first call. For port-critical faults where a vessel is awaiting class clearance to sail, we treat these as emergencies and will work through the night if required. Call our 24/7 line on +44 20 3129 5414.
Related Case Studies and Services
Enquire About Marine CPP Engineering Services
Whether your vessel is in Swansea, Cardiff, or any UK port — contact Ashmit Engineering for CPP control system diagnosis, DNV survey support, and marine electrical repairs.