eRetrofits 25-05-15.cdr

Design & Engineering Solutions for
Environment Protecting Retrofits
Ballast Water
Management
Systems
ENVIRONMENTAL
RETROFITS
(eRetrofits)
Scr ubber and
Dual Fuel
SCR Systems
Engines with
LNG
ABOUT US
Cybermarine is a leading Marine Design & Engineering Enterprise with global operations.
Cybermarine is headquartered in Singapore and controls the worldwide operations through the
offices at Houston and India.
Cybermarine as a company built from scratch, has developed innovative technology and
processes over the years and is in a position to deliver wide ranging design solutions to the
Marine industry. Cybermarine, by utilizing its proficiency in engineering & extensive design
experience has successfully delivered a range of designs for on all types of Cargo Vessels,
Passenger Vessels and landing crafts.
Our technical teams are organized as project teams and operations' teams. Project teams
comprise of project managers and project engineers responsible for project management and client
interaction. Project teams are stationed in all our offices in various geographical locations.
Operations' teams comprising of Naval Architects/Engineers/Designers are responsible for project
Deliveries and class approvals. They are stationed in Mumbai, India and Singapore. We also
have an Offshore Division catering to the Design and Engineering of Drilling assets and Multipurpose support vessels.
As a manifestation of Cybermarine's commitment to producing Green Engineering Solutions for the
Shipping fraternity, we have earmarked a separate Engineering division that endeavors to develop
innovative and refined engineering solutions for various types of vessels that are based on the
progressive criteria laid down by the IMO towards the Environment protection. Our Environmental
Retrofit Solutions (eRetofits) is a part of this endeavor. Our solutions for the implementation of
such green technologies take into the account the various ergonomic and monetary aspects of the
design as well. Comprehensive study of the vendors supplying individual components of such
system has been made by our panel of engineers to provide the ship owners with cost effective
solutions complying with the latest Regulations.
Types of eRetrofit solutions include:
1.
2.
3.
Ballast water Management Systems [Page 2]
Scrubbers & Selective Catalytic Reduction System(SCR) [Page 7]
Dual Fuel Engines with LNG [Page 11]
01
BALLAST WATER MANAGEMENT SYSTEM
Ballast Water Treatment - A Background
Ballast water is taken from one ecological zone and discharged into another by the trading vessels
across the globe potentially causing invasion on local aquatic organism, natural resources and
harming the biodiversity. Maritime community has acknowledged the gravity of the detrimental
impacts that this may have on the local biodiversity, economy or even the human health of
communities in the surrounding areas.
Impending IMO regulations require BWT plants to be installed on most of the existing vessels
around the world.
Cybermarine's systematic retrofit approach ensures the selection of the most suitable technology
that can be integrated into the existing systems and structures and installed in a cost effective
way.
The different technologies for treating the ballast water are:
►
Solid Liquid Separation
o Mechanical Filtration
o Hydrocyclone
o Chemical enchantment (Coagulation / Flocculation)
►
Chemical Disinfection
o Chlorination
o Electro-chlorination
o Ozonation
►
Physical Disinfection
o Ultraviolet Irradiation (UV)
o De-oxygenation
o Cavitation
For most efficient solution the system shall comprises of two stages of treatment with solid liquid
separation method being followed by either of disinfection methods.
There are several technical, operational, geological and cost considerations to be taken into
account while choosing the right BWM solution.
02
BALLAST WATER MANAGEMENT SYSTEM
6
1: STRAINER
2: BALLAST PUMP
3: FILTER
4: CHLORINATING UNIT
5: NEUTRALIZATION UNIT
6: CONTROL MONITORING SYSTEM
7: TOTAL RESIDUAL OXIDANT
ANALYSER
Ballast Water Management System using Chlorinating Unit
1: STRAINER
2: BALLAST PUMP
3: FILTER
4: ULTRAVIOLET IRRADIATION
Ballast Water Management System using Ultraviolet Irradiation
1: STRAINER
2: BALLAST PUMP
3: HYDROCYCLONE
4: WATER TREATMENT TANK
5: EDUCTOR
6: AIR COMPRESSOR
7: AIR DRYER
8: AIR RECEIVER TANK
9: OZONE GENERATOR
Ballast Water Management System using Ozone Generator
03
BALLAST WATER MANAGEMENT SYSTEM
What Cybermarine Offers:
We offer a complete gamut of Design and Engineering solution right from Conception till
Installation.
This is structured in a modular manner from Module 1 to Module 5 thereby allowing our clients to
make their choice ranging from the complete solution to opting out only to part of it such as Detail
Engineering solution and so on.
Why Cybermarine:
A ship specific optimum solution requires extensive cooperation between the Ship owners,
Equipment manufacturer, the Design and Engineering Company and the Shipyard. Cybermarine
with its vast experience in Design and Integration Engineering supported by project management
expertise can ensure a smooth flow of information and time bound installation resulting in minimal
down time for the vessel thus saving money and time.
Only a thorough and good engineering can ensure and guarantee an on time completion of the
project. Cybermarine creates potential for time and money savings by their systematic approach
on design and engineering in the very early stages and avoids surprises and costly delays at the
later stages.
Details of Cybermarine's Offerings:
MODULE 1: Choosing the Right Solution
As your independent Design Consultants we ensure that the most cost efficient and effective
solution is proposed and the right supplier is selected. Thorough ship inspections, feasibility
studies and technology evaluations we compare alternative solutions and their consequences,
taking all the technical, operational and economical aspects into account.
Right choice of optimum solution coupled with smart integration engineering will bring down the
TCO (Total Cost of Ownership) over the life cycle of the system.
04
BALLAST WATER MANAGEMENT SYSTEM
MODULE 2: Collection of Accurate Information
Availability of an Accurate Existing Layout is the foundation to achieving a High Accuracy
Engineering Solution, where necessary, we use laser scanning done by experienced experts to
verify the exact input taken from the ship and Generate a Point Cloud model and then
subsequently an intelligent model of the Reion of the vessel where the system is to be retrofitted.
Point Cloud Model
MODULE 3: Design
The key to a successful retrofit project is a custom made integration design.
As your Design Partners we ensure that all design parameters are carefully considered and right
from achieving a good integration layout and piping Layout to arriving at optimum solutions to
Powering Systems or estimating structural modifications are done. All nitty-gritty & issues are
envisaged at the design stage and costly surprises springing up at later stage are avoided.
05
BALLAST WATER MANAGEMENT SYSTEM
MODULE 4: Detailed Engineering
As your Engineering Partners we ensure that complete gamut of detailed engineering is taken
care of prior to entrusting the job to shipyard, all possible details are foreseen and addressed in
advance so that any last minute changes are avoided. Thouroghly Detailed Layouts, Piping ISOS,
Structural Modification drawings are released to the yard.
Engine Room Model
MODULE 5: Shipyard Support
Successful implementation and an on time completion of the retrofit are facilitated through timely
technical support provided by our team during the implementation phase at the shipyard.
06
SCRUBBER AND SCR SYSTEM
Background - SOx, NOx
Need to save and preserve our planet from Environment pollution has been acknowledged by all
right thinking individuals across the globe and Maritime Community has decided to do it's bit
towards reducing Green house gas emissions.
The IMO ship pollution rules set limits for sulfur oxide and nitrogen oxide emissions from ship
exhausts. Every ship is unique and requires a comprehensive evaluation when selecting and
planning for the optimal solution for the reduction of SOx with Scrubbers and NOx with Selective
Catalytic Reduction (SCR) plants.
The new regulations mean that the limit value for sulphur in the Baltic Sea, the North Sea and the
English Channel (so-called sulphur control areas or Sulphur Emission Control Areas [SECA])
has been lowered to 0.1% of weight in 2015 and globally to 0.5% of weight in 2020 or,
depending on fuel supply, at the latest by 2025.
To comply with the regulation, shipping operators should use lower sulphur fuels or install
technical 'abatement' equipment, such as scrubbers, which achieve equivalent results. An
argument in favour of Liquefied Natural Gas (LNG) as fuel, compared to Heavy Fuel Oil (HFO)
is that it will reduce Carbon Dioxide (CO2) emissions by up to 30% and bring nitrogen oxide
(NOx) emissions to 20% of current levels, which will satisfy the upcoming Tier III emission
requirements without further actions.
Maximum Sulphur content of marine bunker fuel based on Annex VI of MARPOL.
Note:SECA stands for Sulphur Emission control area.
NOx Emmission limit schedule according to IMO
07
SCRUBBER AND SCR SYSTEM
Technologies Available
SCRUBBER SYSTEM
By installing exhaust gas scrubbers, vessels will be able to bring down sulphur content in exhaust
emissions thereby enabling use of fuel currently in usage for marine vessels.
Different types of Scrubber systems are:
►
Open Loop Systems
Seawater alkalinity is used to neutralize the Sulphur in the exhaust and the benefit of the
seawater scrubber is its simplicity; no fresh water or additional chemicals are needed for
operation.
1: SEA WATER COOLING PUMP
2: SCRUBBER
3: WATER TREATMENT UNIT
4: SLUDGE TANK
►
Closed Loop Systems
When the salinity of the water is too low to allow for effective cleaning capability of the
open loop system, closed loop system using fresh water with the addition of a caustic soda
(NaOH) solution is used to neutralize the Sulphur.
1: SEA WATER COOLING PUMP
2: HEAT EXCHANGER
3: SCRUBBER
4: NaOH UNIT
5: CIRCULATING PUMP
6: PROCESS TANK
7: WATER TREATMENT UNIT
8: SLUDGE TANK
9: HOLDING TANK
08
SCRUBBER AND SCR SYSTEM
►
Hybrid Systems
The third alternative for wet scrubbers is a hybrid with an open loop seawater system and
a closed loop freshwater system with the addition of chemicals.
1: SEA WATER COOLING PUMP
2: HEAT EXCHANGER
3: SCRUBBER
4: NaOH UNIT
5: CIRCULATING PUMP
6: PROCESS TANK
7: WATER TREATMENT UNIT
8: SLUDGE TANK
9: HOLDING TANK
1. SEA WATER COOLING PUMP
2. HEAT EXCHANGER
3. SCRUBBER
4. NaOH UNIT
5. CIRCULATING PUMP
6. PROCESS TANK
7. WATER TREATMENT UNIT
8. SLUDGE TANK
9. HOLDING TANK
Closed Loop Scrubber System
09
SCRUBBER AND SCR SYSTEM
SELECTIVE CATALYTIC REDUCTION SYSTEM (SCR)
The main technique used is Selective Catalytic Reduction (SCR), which converts harmful
nitrogen oxides into harmless nitrogen and water with the aid of a catalyst (ammonia or urea). A
NOx reduction level of above 90% can be achieved.
The systems are still quite bulky and there is room for development. Due to temperature
requirements, the catalytic reactor occupies space in the engine casing close to the engine and in
addition a urea tank and a feed system are required. Other techniques such as fuel/water
emulsions and Humid Air Motor (HAM) also exist, but are not that common in the marine
industry.
1: AIR COMPRESSOR
2: NOx REACTOR
3: DOSING UNIT
4: UREA TANK
5: UREA SUPPLY PUMP
What Cybermarine Offers:
Integration Design and Engineering
We will help you in identifying and developing the right method of integrating the system in the
existing vessel with minimum compromise on layout ergonomics.
We will then engineer the entire solution by developing the retrofit design and layouts, detail
engineering drawings, including structural modification plans and generating the bill of material as
per relevant Class Standards. We will also provide technical support during the installation at the
Shipyard.
10
DUAL FUEL ENGINES WITH LNG
Background - LNG Retrofits
We are here to help you to retrofit your existing Diesel/HFO fuel propulsion engines and/or
Generator sets with LNG powered engines or Dual Fuel Engines. This will not only cut the
pollution levels in exhaust gas emissions, but will also reduce your fuel spendings. Various
studies show a significant reduction in the NOX, SOX, GHG on converting from contemporary HFO
engines to dual fuel engines. The table below from IACS publication illustrates the point:
NOx emission
SOx emission
Green House Gases
80-90 % reduction
Zero emission
20-25% reduction
The overall retrofits include:
1.
Dual Fuel Engine
The dual fuel engines of suitable capacity can be selected from a host of makes such
B&W, Watrsalia, Rolls Royce to power the vessel by replacing the existing engines.
2.
LNG Storage Tanks
These are IMO Type-C cryogenic tanks of suitable volume to cater to the needs of the
voyage requirements and to the availability bunkering facility.
3.
LNG Vaporizer and Heater
These units are installed with the LNG Tanks so as to vaporise and condition the LNG fuel
to meet the temeperature/pressure delivery requirements of the engine. Moreover it is also
helpful in maintaining the pressure in the tanks.
4.
Gas Valve Unit (GVU)
This system includes an array of manifolds and valves intended distribute the conditioned
LNG fuel to the individual engines.
5.
Gas Combustion Unit (GCU)
This is an optional system provided to enable the vessel to take care of the boil off gas
produced in the tank in the due course of it's storage.
11
DUAL FUEL ENGINES WITH LNG
The schematic representation of the aforesaid system is shown in the figure:
1: LNG TYPE-’C’ FUEL TANK
2: LNG VEPORIZER
3: GAS HEATER & COOLER
4: GAS VALVE UNIT (GVU)
5: DUAL FUEL ENGINE
6: DUAL FUEL BOILER / GAS
COMBUSTION UNIT (GCU)
7: LNG MANIFOLD
8: HEAVY FUEL OIL DAY TANK
The given modification reduces the SOx, NOx emission to such an extent that it negates the
requirement for the installation of separate scrubber, SCR, EGR systems.
Our Design & Engineering service package includes:
Concept Design Phase
 Identification and Selection of the appropriate components of the system & their possible
vendors.
 Preparing the modification Plan, GA and the Modification Specifications
 Helping the owners in selection of Yard and providing the necessary inputs to them
Detail Engineering Phase
 Preparing Detailed Modification Plans.
 Power Systems Plan, SLD, Fuel Piping and other piping Schematics, Structural Modification
Plans, Stability Calculations, all necessary drawings for Class approvals
 Detailed drawings for issuance of Yard
12
DUAL FUEL ENGINES WITH LNG
What Cybermarine Offers:
Our Sample Retrofit Solution Designs
This design has an Endurance (LNG Bunkering
Cycle) of 8 (eight) days considering normal
Terminal duty with accommodation for 10 Crew and
modular Fuel Tanks.
Propelled by 2 x ASD Thrusters (Direct drive also
available) and 2 x 2, 700kW Generators on Liquid
Fuel / Dual Fuel / Gas Fuel. Design for alternative
Classification Society, Crew strength, propulsion
power others can be made.
This design has an Endurance (LNG Bunkering
Cycle) of 9 (nine) days considering normal
Terminal duty with accommodation for 10 Crew &
Modular Fuel Tanks.
Propelled by 2 x ASD Thrusters (Direct
available) and 3 x 340kW Generators
Fuel / Dual Fuel / Gas Fuel. Design for
Classification Society, Crew strength,
power others can be made.
drive also
on Liquid
alternative
propulsion
This design has an Endurance (LNG Bunkering
Cycle) of 9 (nine) days considering normal
Terminal duty with accommodation for 10 Crew &
Modular Fuel Tanks.
Propelled by 2 x ASD Thrusters (Direct
available) and 3 x 340kW Generators
Fuel / Dual Fuel / Gas Fuel. Design for
Classification Society, Crew strength,
power others can be made.
drive also
on Liquid
alternative
propulsion
This design has an Endurance (LNG Bunkering
Cycle) of 10 (Ten) days considering normal
Terminal duty & accommodations for 32 Crew.
Propelled by 2 x 2000kW Conventional Engine and
3 x 500kW Generators on Liquid Fuel / Dual Fuel
/ Gas Fuel. with LNG Tank installed on the main
deck.
13
Singapore
Houston
10 Bukit Batok Crescent, #12-01
The SPIRE Building,
Mumbai
Kolkata
10101 Harwin Dr Suite 250
501-505, Technocity, Plot No. X-5/3
House No. 02, Block -CD
Houston
TTC Industrial Area,
Sector I, Salt Lake,
Singapore - 658079
TX 77036.
Mahape - MIDC, Navi Mumbai - 400710
Kolkata - 700064
Ph : +65 6316 6513
Ph : 713 988 1784
Ph : +91 22 61462400
Ph : +91 99033 92488
www.cybermarine.net