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Optimizing of Machinery and Propulsion Systems based on Experiences from Teso and IDO operated Ferries Mr. Jorma Tikkanen 7.5.2007 Rolls-Royce Oy Ab Azimuthing thrusters Rauma Finland Double-ended ferry Basic propulsion and machinery selection ; criterias & principles 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. operation route and conditions, shallow water, deep water, ice operation profile ; low speed operation, manoeuvrability and thrust requirements, (margins, route complexity, security, hard wind, sea current and heavy sea), required max. speed for rush hours, transport capacity max. draught calculate estimated propulsion power, ref max. speed, service speed select propulsion type, (open, ducted, crp, pulling, jet) select optimized propeller diameter operation safety, reliability, flexibility, economy, redundancy, availability 365/24, 1 main unit offline => reasonable propulsion power and ship speed (main unit = ME, EM or thruster) single or twin thrusters on both ends, open or ducted construction machinery weight, influence on the ship´s loading capacity Rolls-Royce Oy Ab Azimuthing thrusters Rauma Finland Double-ended ferries Propulsion and machinery concept studies of two different ships built by Damen Shipyards Group Texels Eigen Stoomboot Onderneming TESO M/S Dokter Wagemaker The Netherlands Rolls-Royce Oy Ab Azimuthing thrusters Rauma Finland Istanbul Deniz Otobüsleri IDO Damen Fast Ropax Catamaran Turkey Double-ended ferry Basic information M/S Dokter Wagemaker TESO, The Netherlands Main dimensions Length L = 130.4 m Beam B = 22.7 m Draught max T = 4.4 m Speed economical service = 11.5 kn, design = 15.2 kn, maximum = 15.7 kn (T= 4.1 m) Power total for propulsion = 7.200 kW (traditional diesel-electric drive, 4 pcs Aquamaster US 255 azimuthing thrusters á 1.800 kW, propellers in nozzles, operation margins included). total installed power = 11.424 kW ( 4 pcs diesel-generator sets á 2.856 kW) increased redundancy requirement : maximum speed if one diesel-generator offline Capacity 1.750 passengers, 300 cars / 34 lorries Rolls-Royce Oy Ab Azimuthing thrusters Rauma Finland Double-ended ferry TESO Operation route Rolls-Royce Oy Ab Azimuthing thrusters Rauma Finland Double-ended ferry TESO Operation route Route analysis : Arrival / Departure each 0.25 nm Accelerating / Decelerating each Special features 0.30 nm Transit 1.40 nm Total 2.50 nm Rolls-Royce Oy Ab Azimuthing thrusters Rauma Finland short route speed upto 15.5 kn to maintain regular service strong current upto 3 kn sailing conditions upto wind force 10 Bf shallow water narrow port entries Double-ended ferry Basic information Damen Fast Ropax Catamaran Istanbul Deniz Otobüsleri (IDO), Turkey Main dimensions Length L = 85.0 m Beam B = 21.0 m Speed service = 22 kn @ 90% MCR @ 200 t trial DWT Power traditional diesel-mechanical drive total installed power for propulsion = 6.740 kW 4 pcs Azipull AZP085 azimuthing thrusters 4 pcs Catepillar CAT 3516B diesel-engines á 1.685 kW Capacity 600 passangers, 112 cars 280 t full load DWT Rolls-Royce Oy Ab Azimuthing thrusters Rauma Finland Pendik Terminal Double-ended ferry IDO Operation route Yalova Terminal Rolls-Royce Oy Ab Azimuthing thrusters Rauma Finland Double-ended ferry IDO Operation route Route analysis : Arrival / Departure each 0.40 nm Accelerating 0.40 nm Decelerating 0.60 nm Transit 11.50 nm Total 13.30 nm Rolls-Royce Oy Ab Azimuthing thrusters Rauma Finland Special features Long route Sheltered coastal route Deep water Speed 22 kn Double-ended ferry Operation times on the route TESO 2 min. manoeuvring 2 min acceleration 8 min transit speed (11.5 kn) 4 min deceleration 4 min manoeuvring IDO 2 min. manoeuvring 2 min acceleration 35 min transit speed (22 kn) 3 min deceleration 3 min manoeuvring 20 min scheduled sailing time 45 min scheduled sailing time 10 min unloading / loading unloading / loading 30 min itinerary 60 min itinerary Rolls-Royce Oy Ab Azimuthing thrusters Rauma Finland Power graph Max. power ~ 2 * 2.750 kW = 5.500 kW TESO Max. power ~ 2 * 2.400 kW = 4.800 kW Operation times 1. 2,0 min manoeuvring 2. 2,0 min accelerating 2. 3. 10,0 min transit 3. 4. 4,5 min decelerating 5. 4,0 min manoeuvring 6. unloading / loading, holding the ship against the quay with propulsors. 4. 6. 1. 5. 30 min M/S Dokter Wagemaker The Netherlands Rolls-Royce Oy Ab Azimuthing thrusters Rauma Finland Typical speed vs. time graph 3. Short route Operation times 1. 0,5 min manoeuvring 4. 2. 3,5 min accelerating 3. running in open water • 12 min at service speed (13.0 kn) or 2. • 11 min at increased speed (14.5 kn) or • 10 min at maximum speed (15.7 kn) 4. 2 min active dynamic decelerating 5. < 2 min manoeuvring 6. unloading / loading the ship Graphics : M/F Jakkevarre, Norway Rolls-Royce Oy Ab Azimuthing thrusters Rauma Finland 6. 5. 1. 6. Double-ended ferry Operation times on the route, summary Speed 2 Rolls-Royce Oy Ab Azimuthing thrusters Rauma Finland 4 12 15 18 45 Time min Speed graph Long route Fast ferry concepts Speed Single-ended Double-ended Transit Unloading / Loading Time Rolls-Royce Oy Ab Azimuthing thrusters Rauma Finland Double-ended ferry Design criterias in common for both projects Safety / high redundancy Noise and vibration requirements Environmental demands Flexible installation possibilities Operating profile / conditions / costs Economic demands Rolls-Royce Oy Ab Azimuthing thrusters Rauma Finland Double-ended ferry Design criterias & principles TESO excellent redundancy, operation route and conditions ; shallow water, sea current, hard wind, wind turbulences operation profile ; low speed operation high manoeuvrability high thrust required, ship´s max. speed optimized for route ; transport capacity, rush hours operation ; reliability, high flexibility, good economy, benefits in operation ; acceleration – transit mode - controls Rolls-Royce Oy Ab Azimuthing thrusters Rauma Finland IDO good redundancy, operation route and conditions ; deep water, sheltered coastal route operation profile ; good manoeuvrability ship´s max. speed optimized for route operation ; reliability, economy machinery weight Double-ended ferry Basic propulsion and machinery selection First Priority of Propulsion Systems TESO 1. 2. 3. 4. 5. 6. Rolls-Royce Oy Ab Azimuthing thrusters Rauma Finland High thrust required to secure safety and high manoeuvrability in severe operation conditions Propulsion under emergency condition 1. black out prevention by PMS (Power Management System) 2. crash stop 3. steerability with propulsor (rudder effect with nozzle or tail) Separate propulsion rooms Separate engine rooms Separate switchboard rooms Redundant control, alarm and monitoring Power for propulsion, preliminary study (TESO) 13 different applicable propulsion concepts Hull resistance 1.640 kW @ 12.0 kn System specific hydrodynamic and power transmission losses included Rolls-Royce Oy Ab Azimuthing thrusters Rauma Finland Power for propulsion (TESO) 4 pcs concept candidates Rolls-Royce Oy Ab Azimuthing thrusters Rauma Finland Selection of propulsion Delivered thrust comparison Rolls-Royce Oy Ab Azimuthing thrusters Rauma Finland Propulsion selection Modularized construction D-E FPP D-M CPP Rolls-Royce Oy Ab Azimuthing thrusters Rauma Finland Propulsor input D-M with clutch D-E without clutch D-E FPP D-M CPP D-E CRP D-E FPP D-M CPP Propulsion selection Sample assemblies Rolls-Royce Oy Ab Azimuthing thrusters Rauma Finland Double-ended ferry TESO Propulsion Rolls-Royce Oy Ab Azimuthing thrusters Rauma Finland Propulsion selection Power Range Rolls-Royce Oy Ab Azimuthing thrusters Rauma Finland Double-ended ferry Propulsion and Machinery selection General features for selection Diesel-Electric propulsion Diesel-Mechanic propulsion + DE redundancy flexibility optimum efficiency of the power plant under all operational conditions excellent power management possible low load operation manoeuvrability + DM efficiency in transit mode total weight investment costs Rint de Vries TESO Rolls-Royce Oy Ab Azimuthing thrusters Rauma Finland Selection of propulsion TESO Propulsion´s total input power @ 12.0 kn reference point for calculations 1. US Ducted FPP D-E 2.850 kW 3. Azipull CPP* D-M 2.689 kW Rolls-Royce Oy Ab Azimuthing thrusters Rauma Finland 2. CRP / Contaz D-E 2.599 kW 4. Azipull FPP D-E 2.627 kW Wake, thrust reduction, open water, relative rotative, mechanical etc. efficiencies included acc. to propulsor type. * CPP = 1.015 x FPP Selection of propulsion Performance study Propulsion efficiencies of the power chain 4. 2. 3. 1. 1. Generator = 0.965 5. 2. Switchboard = 0.999 3. Transformer = 0.986 4. Freq. Converter = 0.991 6. 5. Electric Motor, PTO / PTI = 0.965 6. Thruster = 0.975 FPP, 0.960 CPP Wake, thrust reduction, open water, relative rotative etc. efficiencies acc. to propulsor type. Rolls-Royce Oy Ab Azimuthing thrusters Rauma Finland Calculated output power of diesel engines TESO US Ducted FPP D-E CRP / Contaz D-E Azipull CPP** D-M Azipull FPP D-E Diesel engines´ output power in kW (kWb*) @ ship´s speed low speed economical service 9.0 kn 11.5 kn 14.5 kn 1.152 kW 2.685 kW 5.973 kW 1.051 kW 2.448 kW 5.447 kW 997 kW 2.321 kW 5.165 kW 1.062 kW 2.474 kW 5.504 kW max. 15.7 kn 7.859 kW 7.166 kW 6.795 kW 7.241 kW 115.6 105.5 100 106.6 ref value • electric efficiency 0.9099 included, **CPP = 1.015 x FPP • kWe = electric output power of electric motor or generator, kWb = engine´s output brake power • hotel and auxiliaries loads not included Rolls-Royce Oy Ab Azimuthing thrusters Rauma Finland Installed total power for propulsion machinery TESO US Ducted FPP D-E Diesel CRP / Contaz D-E Azipull CPP** D-M Azipull FPP D-E ME AE D total 7.960 kW 7.960 kW 7.280 kW 7.280 kW 6.800 kW 6.800 kW 7.280 kW 7.280 kW Electric AE generators EM, PTO/PTI 7.960 kW 7.400 kW 7.280 kW 6.810 kW - 7.280 kW 6.880 kW E total 15.360 kW 14.090 kW - 14.160 kW • electric efficiency 0.9099 included, **CPP = 1.015 x FPP • kWe = electric output power of electric motor or generator, kWb = engine´s output brake power • hotel and auxiliaries loads not included, increased redundancy power not included, Rolls-Royce Oy Ab Azimuthing thrusters Rauma Finland Propulsion and Machinery Layout TESO Powerplant selection operation flexibility economical operation service, maintenance weight aspect Concept principles Maximized redundancy Maximized thrust Maximized operation flexibility Twin machinery Rolls-Royce Oy Ab Azimuthing thrusters Rauma Finland Double-ended ferry TESO Propulsion and Machinery Layout US Ducted Diesel-Electric (D-E) Propulsion machinery and power plant are divided into two separate departments, one in fore ship and one in after. Rolls-Royce Oy Ab Azimuthing thrusters Rauma Finland Powerplant TESO Diagram by Bakker Sliedrecht, The Netherlands Rolls-Royce Oy Ab Azimuthing thrusters Rauma Finland Bridge control TESO Pilot Bridge control on both ends of the ship Co-pilot Thrust direction Emergency control Each thruster individual or combined Diagram by Bakker Sliedrecht, The Netherlands Rolls-Royce Oy Ab Azimuthing thrusters Rauma Finland Bridge control TESO Rolls-Royce Oy Ab Azimuthing thrusters Rauma Finland Double-ended ferry Damen Fast Ropax Catamaran IDO Rolls-Royce Oy Ab Azimuthing thrusters Rauma Finland Power for propulsion IDO preliminary study Rolls-Royce Oy Ab Azimuthing thrusters Rauma Finland Selection of propulsion Propulsion concept candidates IDO Estimated total power for propulsion @ 22 kn including power chains transmission losses 1. Azipull CPP D-M 6.104 kW Rolls-Royce Oy Ab Azimuthing thrusters Rauma Finland 2. Azipull FPP D-E 6.505 kW Propulsion machinery and its weight basic selection based on Bergen diesel engines nominal power IDO Azipull CPP D-M Azipull FPP D-E Installation ME AE 4 * 1.620 kW - 4 *1.820 kW Weights ME AE EM 4 * 16,0 tn - 4 * 31,0 tn 4 * 8,0 tn Total 64,0 tn 156,0 tn difference Ship´s loading capacity Rolls-Royce Oy Ab Azimuthing thrusters Rauma Finland + 92.0 tn 280 tn full load DWT Double-ended ferry Propulsion and Machinery Layout IDO Conventional Diesel-Mechanic (D-M) Azipull with CPP propellers Main Engine (ME) Shaftline Thruster Auxiliary Engine (AE) Rolls-Royce Oy Ab Azimuthing thrusters Rauma Finland Concept design criterias Maximized flexibility Maximized efficiency Maximized redundancy Ship´s speed Minimizing weight – maximizing ship´s loading capacity Double-ended ferry IDO Bridge control Rolls-Royce Oy Ab Azimuthing thrusters Rauma Finland Double-ended ferry Conclusion Keywords for propulsion and machinery selection safety of operation environment economy highly trained personnel Rolls-Royce Oy Ab Azimuthing thrusters Rauma Finland Ulstein Aquamaster Mr. Jorma Tikkanen Rolls-Royce Oy Ab Azimuthing thrusters Rauma Finland
