The Rolls-Royce marine magazine Issue 28 • September 2016

beyond the horizon Rolls-Royce advanced design and technology opens up a new age of adventure tourism Pages 20-23

Customer focus Leading innovation Latest projects Latest technology On board a fish farm Safe transfers to Radical developments ‘Power by the Hour’ vessel powered by LNG offshore wind turbines in contra-rotation service reduces risks

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ContentsIssue 28 • September 2016

Latest projects

16 20 CONTRA-ROTATION INVESTING IN ADVENTURE Decades of experience in hydrodynamics Norwegian shipping line Hurtigruten and cavitation are vital in providing a radical places an order for up to four new propulsion solution for a hybrid superyacht Rolls-Royce designed explorer vessels

Leading innovation Latest technology Customer focus 10 28 WALK THIS WAY SUSTAINABLY Transferring technicians FEEDING FISH safely and efficiently to LNG-powered vessels are offshore wind turbines playing a key role in keeping the fish fed in Norway’s vast 12 aquaculture industry QUESTIONS ANSWERED Kevin Daffy, Director 30 Engineering & Technology, on A DECADE OF challenges and opportunities NAVAL SUPPORT How a small team providing 14 32 34 in-service support to the PERMANENT MAGNETS REASSESS YOUR RISK TRIED AND TESTED Royal Australian Navy has Rolls-Royce is expanding Rolls-Royce expands its The new MTU marine gas evolved to become a leading its range of permanent innovative marine “Power engine successfully completes provider of fully integrated magnet thruster options by the Hour” service 3,000 hours of bench testing material support

About Indepth magazine People

© Rolls-Royce plc 2016. The information in this publication is the property of Rolls-Royce plc and may not be copied, communicated to a Editor: Andrew Rice third party, or used for any purpose other than that for which it is supplied, without the express written consent of Rolls-Royce plc. While Design: Renny Hutchison; the information is given in good faith, based upon the latest information available to Rolls-Royce plc, no warranty or representation is given Felipe Perez; Raymond Francis concerning such information, which must not be taken as establishing any contractual or other commitment binding upon Rolls-Royce Contributors: Simon Kirby; Silke plc or any of its subsidiary or associated companies. Opinions expressed may not necessarily represent the views of Rolls-Royce or the Rockenstein: Andrew Rice; Craig Taylor; editorial team. The publishers cannot accept liability for errors or omissions. All photographs © Rolls-Royce plc unless otherwise stated. Patrik Wheater; Richard White Production: Connect Publications Ltd

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EditorialThought leadership from our Executives

Despite current economic uncertainties, Rolls-Royce is focused on navigating new markets arising from our experience in different industries and sectors

with mikael mäkinen

nce again, the eyes of the shipping world will O be on Hamburg this September, where the SMM international maritime trade fair takes place. With the rapid pace of technology development in our industry today, and the challenges many have faced because of low oil prices, this year’s SMM promises to be an eye opener for many reasons. There’s no doubt that the digitisation of shipping is happening, and happening fast, so I expect that will be a hot topic once again. The wider availability of new cloud-based technology and big data platforms is going to have a dramatic impact on how the shipping industry manages information, not to mention how it will operate in future. We’re seeing solid growth in the use of data, with owners wanting more real time information to better future technology challenges facing One example is in offshore wind, manage their assets. our customers across all sectors, where the trend is now towards For Rolls-Royce, it means a new not only those involved in offshore. larger turbines operating further out way of thinking, and a new way of What our experience of offshore to sea, beyond the range of smaller running our business. We’re nearing TOP: The Benetti does give us though is a suite of workboats. So, what do you require the completion of a major exercise Vivace 125 yacht Iron proven technology that can be used to carry out these demanding to re-shape our business around Man is the first to be elsewhere, in adjacent markets. tasks and ferry people and fitted with Azipull the future market, and that of Carbon thrusters This year, we’ve been successful equipment safely to these offshore course means shaping our business [Image credit: in landing a range of contracts installations? The answer is a vessel around the future demands Benetti/Quin Bisset] that have involved us taking our with proven capability, excellent of our customers. BOTTOM: Our technology into new and emerging seakeeping and in-built systems vast experience What low oil prices have taught markets, where the demands are to enable the safe and routine in offshore is us is that we need a business with also benefitting surprisingly often quite similar to maintenance of a growing number more balance that can address the renewable energy. those of offshore operators. of offshore windfarms.

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“The need to withstand harsh sea conditions, to operate efficiently, reliably and safely, underpins our product and systems philosophy”

We’ve recently won a repeat ABOVE: Rolls-Royce much of which owes its existence to The past 18 months have rocked order for the latest adaptation of will design and the demands of the North Sea. These many parts of our industry, but in equip explorer cruise our classic UT design, specifically ships for Norway’s ships will feature our wave-piercing some ways this period has created developed around the requirements Hurtigruten. bow, and the Unified Bridge, both a much sharper focus on what of this evolving industry. The originally developed with offshore in lies ahead in technology terms. walk-to-work nature of these ships BELOW: Mikael mind, but now finding favour across Successful navigation of such new means maintenance crews can Mäkinen a range of ship types. It’s been many opportunities will be the key to spend several days at sea, in relative years since we designed a cruise ship, a brighter future. There will be comfort between shifts, much and we’re delighted to be involved in challenges along the way, such as in the way those serving oil and this very significant project. uncertainties in the world economy, gas platforms do. Another area I expect to hear but there is a clear drive to move The need to withstand more about in future is the use of shipping to a new age. harsh sea conditions, to operate alternative materials and smart Digitisation is coming, and there efficiently, reliably and safely, manufacturing techniques. Across is a growing demand for ships to be underpins our product and systems Rolls-Royce we have access to an increasingly efficient – that will see philosophy. That’s meant that extensive range of know-how in more players adopting new digital we’ve had to develop solutions these technologies, developed for business models. So there is no that are mission critical and our numerous markets. The use of much doubt about our industry being in customers can rely on. lighter carbon fibre materials in transition, which could perhaps see Another new market opportunity our jet engines is quite advanced, more consolidation. Such transition is an exciting project for Norway’s and we’re now taking this to our is an exciting prospect, and if you’re Hurtigruten, who are developing marine portfolio. prepared to embrace change, the a new generation of explorer This year we delivered our first opportunities will come. cruise ships to operate in Arctic Azipull Carbon thruster, a significant waters. It’s a destination growing proportion of which is manufactured in popularity with passengers from carbon fibre. Aimed initially who want an experience just at the yacht market, its lightweight www.rolls-royce.com/ products-and-services/marine that little bit different. Read more construction and hydrodynamic marineinfo about it on page 18. characteristics give us another @rolls-royce.com These vessels will incorporate exciting prospect for the future – you www.linkedin.com/ a range of Rolls-Royce technology, can read more on page 8. company/rolls-royce

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Vision for autonomous ships published The Rolls-Royce led Advanced Autonomous Waterborne Applications The latest developments across Rolls-Royce marine Initiative (AAWA) published a white paper to coincide with its presentations at the Autonomous Ship Technology Symposium 2016 in Amsterdam. The white paper outlines the project’s £44m investment in vision of how remote and autonomous shipping will become a reality. thruster manufacture It explores the research carried out on the business Rolls-Royce is planning a major case for autonomous programme of investment in its applications, the safety and azimuth thruster production facility security implications of in Rauma, Finland, consolidating designing and operating assembly and test capability and remotely operated ships, modernising the operation to the legal and regulatory position the business for future dimensions and the growth opportunities. existence and readiness The €57m* (£44m) project will of a supplier network include a major rebuild of existing to deliver commercially facilities, the transfer of thruster applicable products. assembly and testing on to one site The white paper draws from the existing two locations, on a range of expertise and a significant investment from academic researchers in new equipment. from some of Finland’s Rauma produces a wide range of leading universities: mechanical azimuth thrusters for Tampere University of use across a number of applications, Technology; VTT Technical including semi-submersible drilling Research Centre of Finland rigs and drillships, tugs and offshore Ltd; Åbo Akademi University; vessels, to icebreakers and polar Aalto University, and the research ships. University of Turku. Industry Mikael Mäkinen, President – input has been provided Marine, said: “Our azimuth thrusters by leading members of the are one of our most important maritime cluster including products, providing mission critical Rolls-Royce, Brighthouse power and propulsion for some NAPA, Deltamarin, DNV of the largest floating objects on ABOVE: Azimuth will allow us to plan for the future, GL and Inmarsat. the planet. To be able to make this thrusters are among enable us to efficiently produce our The project also has the the largest products significant investment in Rauma existing range and develop new and support of shipowners and designed and not only prepares us for future manufactured by larger mechanical thrusters.” operators. The tests of sensor growth in this market, but is a vote Rolls-Royce and the The largest and most powerful arrays are being carried out of confidence in the capability and range is extensive. thrusters are the ARC type, which aboard the Finferries 65 expertise of our people.” power icebreakers such as Finland’s metre double-ended ferry, BELOW: Olli Olli Rantanen, Finland, Managing Rantanen, Managing Fennica and Nordica. They are the Stella. ESL Shipping Director, added: “Since the first Director of the among the largest products Ltd is helping explore the azimuth thruster was developed Rauma site. produced by Rolls-Royce and each implications for the short here in Rauma over 50 years ago, weighs up to 190 tonnes, providing sea cargo sector. these products have become the 7.5Mw of power. Download the white paper at: standard choice for customers The work to transform Rauma www.rolls-royce.com/products- demanding very high levels of will begin immediately and is due and-services/marine/services/ reliability, power and performance, for completion in 2020. ship-intelligence/remote-and- autonomous-operations.aspx often in extremely challenging (*Based on an exchange environments. This investment rate of €0.775)

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First chemical tanker enters service The first of four 15,000dwt slamming and lower accelerations chemical tankers ordered by in the fore of the ship. As Swedish tanker owner Terntank they will operate in Northern Rederi AS from the AVIC Dingheng European waters, the tankers Shipbuilding yard in China is satisfy Terntank’s demands for scheduled to enter service in minimal environmental impact Europe during August, after and will run efficiently on LNG as successfully completing sea well as diesel. trials in May. The second tanker in the Named Tersund, the vessel will series, named Ternfjord, was be deployed under a time charter © AVIC delivered in August with the with Finnish North European remaining newbuilds scheduled Oil Trade OY (NEOT), primarily wave-piercing bow design from the ABOVE: Ternsund, a for delivery at the end of distributing refined oil products award-winning Environship. Rolls-Royce NVC 615 2016 and the beginning from NEOT’s Gothenburg refinery The hull design offers up to design, on sea trials. of 2017. As well as the BELOW: Bunkering With a length of 147m and a eight per cent less hull resistance for the first time in base design for the beam of 22m, the tankers of and improves vessel performance Rotterdam. (Credit: tankers, Rolls-Royce supplied Rolls-Royce NVC 615 CT design in a seaway, with less speed loss Port of Rotterdam) tunnel thruster, deck machinery feature the slender hull and in heavy seas, less bow impact and and steering gear.

Subsea system installed Modifications to convert the 157m The contract was with Ocean Aker Wayfarer to a deepwater subsea Yield ASA, and the vessel is under support vessel have been completed long-term charter with Aker Oilfield on schedule at the Kleven Myklebust Services (AKOFS). The contract with Verft yard in Norway. Petrobras is set to start in the fourth A major part of the work was the quarter of 2016. Before moving to installation of a Rolls-Royce subsea Brazil, the vessel was undertaking module handling system. work in the North Sea. This comprised a fibre-rope A similar fibre-rope system was deployment system (FRDS) based on fitted on the AKOFS-operated subsea patented cable traction control unit support vessel Skandi Santos in technology, deck skidding systems 2009, to install and retrieve subsea and a subsea orientation equipment trees and modules in depths system. The system will enable the up to 2,200 meters. In 2014, the vessel to install and retrieve subsea number of installations undertaken trees and modules, including subsea increased from 28 per cent to 44 per structures and manifolds. cent of Petrobras’s total. It found The modifications were the vessel to be one of the most undertaken so the vessel could efficient and reliable in its fleet, perform subsea intervention services reducing installation time by up ABOVE: The tower for subsea module handling with fibre rope being offshore Brazil for Petrobras. to 50 per cent. installed on Aker Wayferer. [Image credit: Kleven/Tor Erik Kvalsvik]

rolls-royce indepth magazine 07 upfront First MT30 powered frigate launched

The Republic of Korea’s first FFXII one of the most advanced frigates in frigate of the new Daegu-class terms of acoustic signature among has been launched by Daewoo western navies. Shipbuilding and Engineering The configuration is similar (DSME) at its Okpo yard to that adopted for the US Navy’s in South Korea. Zumwalt-class destroyers, the Royal Slightly larger than the FFX Batch Navy’s QE class aircraft carriers and I Incheon class, with an overall length future Type 26 Global Combat Ship. of 122m, the Batch II variant retains The MT30 gas turbine was built most of the main core ship systems, and tested in Bristol, UK and was with the main difference being the then integrated into a compact steel propulsion arrangement. enclosure, with air inlet, exhaust and Earlier FFX-I frigates have a ancillary equipment by local partner CODOG mechanical propulsion generators will supply the ship’s ABOVE: The first Hyundai Heavy Industries, Engine & arrangement that uses two power and propulsion needs with Rolls-Royce MT30 Machinery Division. powered FFXII propulsion diesels, four diesel a single Rolls-Royce MT30 providing Daegu-class frigate Rolls-Royce also delivered the generator sets for ships electrical additional propulsion power for has been launched CP propellers and during 2016 will power and two gas turbines for higher speeds. at DSME for the supporting commissioning of the propulsion. The FFX-II CODLOG This has reduced the number of Republic of Korea propulsion system. propulsion arrangement has two power units per frigate from eight Navy. [Image credit: The first FFX-II carries the DSME] permanent magnet propulsion to five, an arrangement that offers pennant number 818 and is named motors and four diesel generators significant cost, weight and space Daegu. It is scheduled for delivery plus a single gas turbine. savings with reduced maintenance to the RoK Navy in late 2017 with MTU 12V 4000 M53B diesel requirements. It also makes FFXII commissioning a year later.

Innovative propulsion for Benetti Rolls-Royce has signed a contract with the Italian yacht builder Benetti to deliver a new generation of high- performance, lightweight, steerable thrusters that make comprehensive use of carbon fibre material for the first time. © Benetti Yachts “Efficient and lightweight propulsion is key to reducing the environmental impact of a modern ABOVE: Aimed better vessel lay out while maintaining including propeller. The buoyancy yacht,” said Vincenzo Poerio, Benetti at fast yachts and high propulsion efficiency, excellent in seawater is about 990kg, which CEO. “We have been working closely later passenger manoeuvring and easy maintenance. makes the effective weight of the vessels and with Rolls-Royce on a journey workboats, the The first thruster in this series, the underwater unit approximately towards an excellent propulsion Azipull Carbon AZP C65, has a power rating of 2MW 660kg when the vessel is afloat. system for our new line of exclusive brings to the market and is fitted with a fixed pitch pulling The contract covers a number of megayachts. The successful result a lightweight, propeller. The driveline is designed thrusters, planned for delivery over reliable and highly of this collaboration has been with two spiral bevel gear sets. the next three years to RINA Rules efficient propulsion confirmed by facts; indeed, five units system with very Steering is hydraulic and integrated for Classification of Yachts. have already been sold and more low noise and to a compact bearing arrangement The first yacht, a Benetti Class Fast units are already under construction vibration levels. and patented hull-fitting structure. Displacement Vivace 125’ called Iron to shorten delivery time and face the Total weight of each Azipull Man, has been delivered. Hulls no. increasing demand for this model.” Carbon is 2,800kg (dry). The weight 2 and 3 are under construction and The use of carbon fibre for load of the inboard part is 1,150kg planned for delivery in the next few carrying parts has substantially (approx.) and the hydrodynamic months. Two 1,965kW MTU 16V 2000 reduced propulsor weight, facilitated a underwater unit 1,650kg (approx.) M94 engines provide the power.

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Marine Mooring events the world’s September 6-9: SMM first offshore 18-20: CFOA 19-21: Marintec fishfarm South America The world’s first offshore fishfarm “This contract win shows how ABOVE: A Rolls-Royce 20-25: SNI eight-point mooring installation is now being developed years of experience providing 28-1 Oct: system will moor the for Ocean Farming AS, a subsidiary sophisticated mooring and deck semi-submersible, Monaco Yacht Show of the Norway’s SalMar Group, one machinery solutions in some of the rigid structure to of the world’s largest producers world’s most difficult sea conditions the seabed. [Image October of farmed salmon. can be applied in other areas of the credit: Salmar] Moving further offshore enables maritime economy today and for 17-21: Euronaval industry growth and harnesses the future,” said Asbjørn Skaro, EVP 31-2 Nov: environmental conditions that are Deck Machinery. Seatrade Middle East best suited for healthy fish stocks. “The technical solutions for However, moving to deeper water SalMar’s pilot installation is based also requires new technology. on the state-of-the-art technology November Rolls-Royce has signed a contract Norwegian industry has to offer 5-9: Ft Lauderdale for the construction and delivery from both fields of aquaculture and Boat Show of an eight-point mooring system offshore oil and gas.” that will secure the rig to the The eight-point mooring MORE 7-10: ADIPEC ON DiGITAL 29-2 Dec: ExpoNaval seabed at Frohavet, off the coast of system from Rolls-Royce includes For extra central Norway. monitoring, fairleads, connectors dynamic content, The 68m high semi-submersible and subsea load sensing system. download the December rig will have a diameter of 110m The new semi-submersible digital edition of Indepth 3 30 Nov-2: Workboat Show with a volume of 250,000m and is rig will be constructed at Qingdao from iTunes or intended for installation in water Wuchuan Heavy Industry Co. Ltd Google Play depths of 100 to 300m. in China.

Knut Müller, Head of Marine ‘America’s Tall Ship’ repowered and Defence business at Rolls-Royce Power Systems, said: “MTU’s Series The US Coast Guard’s barque Eagle, 4000 engines offer unrivalled power also known as ‘America’s Tall Ship’ Now 80 years old, density in terms of volume-to- the US Coast Guard is to be repowered with a Series cutter Eagle is to be power and power-to-weight ratio, 4000 MTU engine. The training repowered with an MTU and are certified by the American ship was initially built for the 8V 4000 marine diesel Bureau of Shipping’s (ABS) Naval German Navy in 1936. propulsion engine. Vessel Rules (NVR). With three-masts and a length “The Series 4000’s advanced of 59.4m (195ft) the Eagle can technology ensures security at sea reach 17 knots under full sail. It will with exceptional fuel efficiency receive one MTU 8V 4000 marine and reliability. The engine’s low propulsion engine for use when the noise characteristics are attributed cutter is not sailing. The repower to a resilient mount system will also include MTU Callosum – an that comes standard on all MTU integrated ship automation system marine engines.” that allows operators to monitor The Series 4000 marine engine the propulsion plant, the on-board will be provided by a team led by power supply and the entire ship. By powering the Eagle BMT Designers & Planners Mike Rizzo, Government Naval with an MTU Series of Alexandria, Virginia. Programme Manager at MTU 4000 engine, cadets MTU distributor Johnson America Inc., said: “The biggest will be able to directly & Towers will supervise benefit the US Coast Guard has translate their experience installation and conduct in turning to MTU is consistency on the training cutter product training, while in its fleet. The US Coast Guard to other MTU-powered MTU will offer engineering has many MTU-powered vessels. vessels in the fleet.” programme support.

rolls-royce indepth magazine 09 leading innovation

Transferring technicians and engineers across open sea to an offshore wind turbine can be a challenging operation. Rolls-Royce dynamic positioning systems and its UT design vessel are the perfect combination to ensure efficiency and safety

Walk this way

ABOVE: The DP words: simon kirby vessel to work on DONG Energy’s complete each collection or delivery, Hornsea Project One windfarm, system is integrated a DP system able to establish with the operation 120km off the UK’s Yorkshire coast of the gangway. optimum performance very ow did you get to work in the North Sea. quickly on arrival is essential to today? Hopefully it did The 81m SOV can accommodate BELOW: Smaller fulfil the vessel’s design brief,” not involve crossing up to 40 wind turbine technicians support vessels says Arnt-Ove Austnes, General H a gangway across and has to ferry six to eight use the SOV as a Manager Sales – Electrical, mothership. open sea to a small doorway some maintenance teams to and from a Automation & Control. metres away. However, that’s the similar number of wind turbines By comparison, in the offshore reality for the growing number of at the start and end of each shift. sector there are often site specific engineers and technicians servicing Therefore, there is only about operational guidelines which state Europe’s offshore wind industry. 20 minutes for each delivery or a vessel has to be on DP for half an Recent Rolls-Royce developments in collection. Technicians walk to work hour or so outside a 500m zone, DP systems have been centred on across a specially designed motion before approaching the platform improving these working conditions compensated gangway, which is and conducting its mission. “In and have contributed to the award- hydraulically raised or lowered on a winning UT 540 service operation pedestal, to give safe and level access vessel (SOV), specifically designed to the turbine platform at different for windfarm support activities in states of the tide. shallow waters. The three-model UT 5400-series Optimum performance has been developed to serve as the To enable safe working in close base for wind turbine technicians proximity to the turbine towers, while they perform maintenance. the UT540 is equipped with DP2 The first UT 540 was ordered in dynamic positioning. But the role 2015 by Østensjø Rederi to support of the vessel and the consequent work on DONG Energy’s Race demands on the DP system are Bank offshore windfarm, 27km off very different from those in the the coast of Lincolnshire, UK. The offshore industry. company has now ordered a second “With only 20 minutes to UT54010 rolls-royce indepth magazine MORE ON DiGITAL See a simulation of the windfarm vessel by downloading our digital issue of Indepth

effect,” adds Austnes, “for windfarm consequently saving fuel. support we’re doing this twice as “At the heart of a DP system According to Johan Rokstad, fast as we’ve done previously.” Østensjø Rederi CEO, the UT 540 “At the heart of a DP system,” is a complex mathematical “enables us to expand our business according to Frode Bloch, Technical into the renewable energy sector. Product Manager – positioning model using a combination We believe the sector holds further and thruster controls, “is a complex of data to position the ship” demands for similar vessels in mathematical model using a the near future. combination of data to position the “When building a new vessel our ship. In the case of the Race Bank Rapid change of function ABOVE: Vessels focus is to make sure it is optimised array, the vessel uses GPS and lasers Once the turbine transfer operation like the UT 540 for the operation it is set to perform. are designed to fired from a spinning unit at the top is concluded, the DP system In choosing a partner, we look for accommodate and of the vessel and reflected back from undertakes the vessel’s transit phase, transport six to someone who can incorporate discs on the turbine together with moving to the next turbine at up to eight wind turbine innovative solutions, efficient hull weather and current information to 13knots powered by four 4000-series maintenance teams. design and positive environmental carry out its role. MTU diesels. This requires a rapid effects into the design. For this “This takes time and to meet the change of function for the DP project we chose a Rolls-Royce vessel’s schedule we had to speed up system, from station-keeping design. The new vessel is the result of this process up while maintaining to navigation. a positive collaborative process with the system’s integrity using some After deploying the maintenance the team there. Our requirements additional mathematics.” teams, the vessel has to wait have been transformed into an SOV The DP system also needs to several hours while the work is vessel that will provide a safe and be integrated with the operation done, before collecting them at efficient walk-to-work experience for of the gangway. the end of the shift. During that our wind technicians.” As the gangway is not a time, the vessel takes advantage permanent connection it cannot of another DP function – ‘weather be used as a positioning reference, optimal positioning’. This More information email: but still needs monitoring by the automatically maintains the [email protected] crew using a panel on the DP vessel’s ideal position using the See a simulation of the windfarm vessel user interface. minimum number of thrusters and in action on our digital edition of Indepth UT540rolls-royce indepth magazine 11 leading innovation Questi ns answeredMarine engineering and technology at Rolls-Royce is led by Kevin Daffy, who took up the post following Hugh Clayton’s move to lead transformation across Rolls-Royce earlier this year. Indepth caught up with him to get his insight into the current challenges and opportunities

Can you describe your career to date and the Royal Navy’s subject matter expert for Another challenge for our engineers how it has prepared you for your current Electrical and Control Systems. Spending is to strengthen the link between our role and shaped your approach? time in a customer organisation gave me development and manufacturing Before joining Rolls-Royce I gained an awareness of what it’s like to be one of capabilities. For example, our Azipull experience in engineering and our customers on the receiving end of our Carbon has recently been introduced to commissioning products for a lot of products and services. the superyacht market. Customers see different industries, including steel, paper, On return to Rolls-Royce I became head the value in having a lightweight but mining, cranes and wind tunnels. This of the Electrical Power and Control Systems high power, low vibration product. As strong industrial background, which also Group looking after the electrical and that demand increases we will need the included marine, means I am familiar controls systems capability for the group, manufacturing systems to volume build, with the types of products we supply and and in February this year I took on this role. but in a cost-effective, repeatable way. I have a good working knowledge of the marine requirements. What are the main engineering and What should our response be? I started my career as a service engineer, technology challenges facing the business? We have access to some phenomenal commissioning automation and electrical Product safety is our number one priority. resources at Rolls-Royce, which I want to equipment systems in steel rolling mills We must ensure our customers and our harness more effectively. I want to harness around the world for GEC Electrical own employees are safe when they install the brainpower of our 15,000 engineers Projects, before moving into engineering or use our products. worldwide along with the expertise of management. I was chief engineer for the As a marine business, we need to our Fellows, University Technology Centres electrical power and propulsion system get better at electrical systems. We’ve (UTCs) and the capability developed in of the Type 45 Destroyer programme on predominantly been a mechanical company other parts of the business, to help our behalf of Alstom, a role that ensured I – for example, mechanical propulsion and 1,400 engineers in Marine develop and gained excellent commercial and project hydraulic deck machinery – but ships are deliver the innovative products and services management experience. In 2002 I was becoming increasingly electric. We must our customers need. promoted to become chief engineer for supply more of the electrical systems and Some of the technologies we’re Alstom’s marine power and propulsion become a serious player in the market. developing in Ship Intelligence are already systems. So my early career gave me a broad Ship Intelligence is beginning to exploiting that capability. They include engineering and delivery background. disrupt how the marine industry is Rolls-Royce Digital, the company’s Software In 2003 I joined Rolls-Royce and structured. There are three strands; health Centre of Excellence, Strategic Research the newly formed Marine Electrical management, optimisation and remote/ Centre and UTCs. As we develop production Systems Group based in Bristol, working autonomous ships, all enabled through systems for our Carbon Azipull technology predominately on Naval power and digital technology and big data. By we’re also drawing on specialist resources propulsion systems including those helping our customers exploit the massive in the Materials Group with access to the for the Queen Elizabeth Aircraft Carrier. amount of available ship data, we will UK’s National Composites Centre in Bristol. I spent time in Portsmouth as chief create new services to optimise operations engineer for the former VT Controls Ltd, or to help us guarantee availability of Given the range of Rolls-Royce technology, which Rolls-Royce acquired in 2003, and power and propulsion systems and offer how do you decide what is important? led a large engineering team delivering Power-by-the-Hour contracts. Our aim is It’s about having a complete and naval switchboards and Platform to use software and automation to build accurate picture of how the business Management Systems. long-term relationships with customers can help customers increase revenue or During 2007 I left Rolls-Royce for a three that reduce their costs while generating save operating costs, and then tailoring year Ministry of Defence secondment as service revenues, similar to our aerospace our products and services to match. their chief marine engineer. Here I had two aftermarket business. We harness in-service This will enable us to identify the right roles; firstly as a Naval Authority officer product data to enhance our ongoing technologies. For instance, we know how for Power and Propulsion systems, signing product development to improve reliability hybrid-electric power and propulsion off warships to go to sea, and secondly as and efficiency. can save fuel and enhance operational

12 rolls-royce indepth magazine “On Ship Intelligence, spending is considerable and we are deploying some 50 people to deliver the associated programmes” Kevin Daffy

flexibility, so we are strengthening our electrical systems capability to include integrating large battery arrays and the continued development of our permanent magnet motor technology for thrusters and winches.

We announced a 50 per cent increase in marine R&D for 2016 – how is this progressing? Even though our 2016 revenue is expected to be lower than 2015, our R&D spending has increased as proportion of revenue from 2.8 per cent in 2015 to 3.5 per cent in 2016. This is a significant investment in technology and products, but it’s right to do this when market conditions are tough. We have several exciting product development programmes in progress such as the Next Generation Thruster, Compact Pod, PM winch, fibre rope crane, enhancements to the Unified Bridge and Next Generation Low Voltage Propulsion Drives. On Ship Intelligence, spending is considerable and we are deploying some 50 people to deliver the associated programmes.

What is the best part of your job? I travel a lot and I’m rewarded with great people at the end of every journey. I enjoy meeting people with different skills and backgrounds who are passionate about the marine industry, they’re passionate about our customers and they understand our customers’ operational challenges.

What do you do to unwind? I am a keen road cyclist. I recently completed the Velothon Wales, cycling 87 miles (140km) with more than 2,000 metres of ascents.

Send an email to [email protected]

rolls-royce indepth magazine 13 leading innovation Magnetic

Effectively harnessing the compact power of permanent magnet thrusttechnology is expanding the number of Rolls-Royce thruster options

lubricated by EAL (environmentally words: richard white acceptable lubricant). Much of the technology and Introducing the AZ-PM 1900… experience from development he permanent magnet of permanent magnet tunnel azimuth truster [AZ-PM] thrusters (TT-PM range) transfers from Rolls-Royce to the new AZ-PM 1900. The key T combines a ring-type development is integrating the permanent magnet electric motor, motor stator into an efficient propeller and nozzle in a tightly nozzle and designing an advanced integrated propulsion unit. It offers propeller with maximum resistance improved efficiency, simplicity and to cavitation and low noise. ease of installation compared to As with all Rolls-Royce propulsion conventional geared azimuth products extensive CFD studies thrusters with separate electric were undertaken to maximise motors in the thruster room. hydrodynamic efficiency. The nozzle As the motor rotor forms a ring shape come from extensive research around the propeller blades and the ensuring the AZ-PM 1900 can advanced blade shape, cavitation provide high efficiency at speeds is suppressed or eliminated. The from towing up to around 16 knots. motor stator is incorporated in Two AZ-PM 1900 technology the nozzle, which controls water demonstrators were fitted for a long flow and provides increased thrust term evaluation programme on the over a wide speed range. The research ship Gunnerus in 2015. They underwater unit can be rotated are rated at 500kW to match the test 360° to give vectored thrust in any vessel’s available power, however direction. A steel structure carries the propeller diameter is generous the steering bearing and the unit is for the loading, so a thruster with simply bolted into the hull. A small the same diameter nozzle can footprint with limited headroom is handle up to 1,100kW. required in the thruster room as the Since the conversion was only components there are the slip from shaftlines and rudders to ring case and the compact electric PM azimuth thrusters retaining steering motors. Speed control is by the existing generator sets, exact varying the frequency of the current comparisons can be made. Bollard supplied to the motor. pull has increased by 20 per cent Motor efficiency is at 97 per and speed by about one knot for cent or more over the load range, the same power. Course stability is and the submerged motor means good, and manoeuvrability greatly that no additional cooling is improved. Station keeping and required, saving space and reducing ABOVE: The new AZ-PM permanent magnet azimuth thrusters have the propulsion thrust response are installation cost. Simple bearings in motor stator incorporated into the nozzle, with the rotor forming a ring better. Noise readings are similar or the rotor hub carry all loads and are around the propeller blades. ABOVE RIGHT: Mounted on Gunnerus. lower. More than 1,500 hours have

14 rolls-royce indepth magazine Magnetic thrust

been accumulated troublefree. unit, but with a vertical shaft BELOW: The Azipull All are in use on existing Azipull “Developing the AZ-PM 1900 has permanent magnet (PM) motor AZP-PM 120, models. If a fixed pitch propeller involved engineers in many fields integrated into a new upper unit. L-drive is powered is selected speed is controlled by by a compact including electrical, mechanical, Combined with the proven high shaft mounted varying the frequency of the current hydrodynamics and materials, propulsive and hydrodynamic permanent magnet supplied to the motor. For a CP and we are happy that the test efficiency of the Azipull, this will be motor and is rated installation both rotational speed programme with Gunnerus has winning combination. The PM motor at 1,800 – 3,500kW. and propeller pitch can be varied Its small motor size validated the concept,” says Agathe maintains a very high efficiency means it will fit with the Rolls-Royce combinator Kalvatn, Technical Product Manager. over a wide speed range and space within the diameter control system. The fully feathering “The AZ-PM 1900 covers a power requirements in the thruster of the mounting version has the same merits as the range from 0.5MW to 1.1MW, the room are reduced. A compact PM flange. CP propeller, but the ability to align type number denoting the effective motor fits within the diameter the blades with the water flow to propeller diameter. The team is now of the mounting flange giving a minimise drag when the thruster is working on extending the size range small footprint and eliminates an not powered. This is advantageous to 2.6MW during 2017.” upper gearbox, thereby avoiding for installations in multifunctional the complication of a coupling, vessels and others such as double …and the AZP-PM, L-drive foundations and motor for a ended ferries, where the aft unit zipull thrusters with conventional Z or C-drive. is normally powered, the other pulling propeller and Installation is significantly fully feathered. streamlined underwater simplified with the introduction the Being introduced from 2017 A skeg have proved new weld-in tube hull fitting. This is the AZP-PM 120, rated at 1,800 popular propulsion units since they is a cylindrical steel element with -3,500kW continuous. This will be were introduced in 2003. Over six a conical section to the mounting followed by two smaller frame sizes, hundred units have been flange, which is easy to weld into 085 and 100, and one larger, the 150. manufactured to date with either the vessel’s hull structure, They will be available in due course direct mechanical transmission, or a especially for a thruster inclined in for powers from 900kW to 5,000kW separate electric motor. all directions. and speeds up to 24 knots. From 2017 a new Azipull AZP-PM Three propeller types will be model will be added. It will have offered for the AZP-PM, with the an L-drive configuration using choice dependent on the For more information email: essentially the same underwater vessel and its operation. [email protected]

rolls-royce indepth magazine 15 leading innovation Contra-

rotationDecades of experience in studying hydrodynamics and cavitation are vital in meeting critical customer requirements, especially when they are on the edge of known knowledge

MORE ON DiGITAL For extra dynamic content, download the digital edition of Indepth from iTunes or Google Play

were still a number of risks to mitigate.” out. Further innovation includes a floating words: simon kirby So began a five-year programme, which superstructure, an underwater lounge and combined state-of-the-art hydrodynamic ‘open’ aft deck areas. When Feadship asked us to research with the development and adoption provide the propulsion for their of ground-breaking new design tools. Unique product combination innovative new ‘Breathe’ hull The result sits below a striking new The Rolls-Royce contribution to the vessel’s design, requiring a number superyacht, the 83.5m Savannah, which pioneering electromechanical propulsion of different propulsion modes for different claims to be the first hybrid motoryacht. platform was a unique combination conditions, we weren’t sure it could be Featuring an eco-friendly blend of single of a number of existing but separate done,” says Göran Grunditz, Manager of the diesel engine, three gensets, batteries, products in a new way. Rolls-Royce Hydrodynamic Research Centre CP propeller, azimuth thruster and a A large CP propeller, rotating in a counter in Sweden. “We’d been researching contra- streamlined hull shape, the vessel offers clockwise direction, when viewed from rotating propulsion on and off for more than improved fuel economy of 30 per cent, aft, was installed in front of an Azipull 30 years, but we knew we had not delivered quiet cruising at low speeds on battery unit with its propeller rotating in the something this radical before and there power and extra speed when going flat opposite, clockwise direction to create a

16 rolls-royce indepth magazine Image © Feadship

contra-rotating propulsion system located front of the forward propeller, also presents a as far as the 1980s,” says Grunditz. along the vessel’s centreline. Operating in design challenge. It creates a reduced water A key challenge identified was the extent the rotational slipstream of the forward flow over the first propeller. This improves of the dynamic loads the configuration propeller, the aft propeller recovers energy the overall efficiency of the vessel, placed on the aft propeller blades that from the swirl it creates. This energy but the flow is non-uniform and operate in the slip stream of the forward would otherwise be lost, making at the propeller causes noise one. They were identified as being at their the system more efficient than a and vibration. That meant a worst when the Azipull is being used to steer. conventional twin screw. special, bespoke propeller These dynamic loads could increase wear on The Azipull also provides design was required to internal bearings and gear wheels causing excellent low-speed manoeuvring maximise efficiency with them to fail prematurely, and could even so there is no need for a tunnel minimum noise. damage propeller blades. thruster in the aft skeg. That means “To develop the system One of the factors that helped less drag, further contributing to we began by reviewing solve this is that in contra-rotating energy saving. the existing research that mode at high speeds the Azipull However, the skeg, located in had been done, going back does not steer – separate rudders

RIGHT: Göran Grunditz rolls-royce indepth magazine 17 leading innovation

“Rolls-Royce is probably the only company that could have developed and produced this ground-breaking system for this innovative vessel”

The Azpull azimuth thruster is mounted on robust custom design supports to minimise vibration. All photos © Feadship

are used. The rudders also limit the worked with the yard and another allowed us to estimate the optimum power freedom of movement of the Azipull specialist supplier to mount the Azipull on distribution for the forward and aft propeller, at speed, further reducing the risk of robust custom-designed elastic supports, optimum shaft speeds and propeller high dynamic load. something never done before. The special pitch for both, giving a starting point for At slow speeds and when operating in supports reduced the impact of vibrations detailed design.” DP the yacht is manoeuvred using the 360° caused by the propeller and were confirmed Another set of design tools were used for thrust vectoring of the Azipull, while the as effective during sea trials. Studies found the detailed design, which took account of forward propeller is feathered. That provides some resonances but they were all low in propeller interaction effects. excellent manoeuvrability with marginal magnitude, so there was no need for any “CFD tells us a lot,” adds Johansson. impact from the forward propeller. restrictions, such as RPM. “We found additional information from Designers also worried about the way CFD simulations. We used it to explore the in which the natural frequency of the Research and design tools interaction between the hull and the contra- Azipull corresponds to the blade pass Rolls-Royce designers made extensive use rotating propellers so dynamic loads on the speeds of the propeller. A contra-rotating of innovative Computational Fluid Dynamic Azipull could be predicted and understand propeller uses a lower than normal shaft (CFD) tools to design and validate the the implications of swirl on the rear propeller. speed and experiences different excitation propulsion system. It also allowed us to go through multiple frequencies compared to a conventional “We developed a tool to evaluate the design loops before arriving at the optimum propeller. This means that the torque is performance of the CRP set up, predicting design, which was then model tested, saving higher for the same power, which can lead efficiency for combinations of propeller pitch time and money. Model testing validates to lower safety margins of gearwheels when and RPM,” says Rikard Johansson, Senior the fundamental physics of the CFD model, dynamic loadings are considered. In this Hydrodynamicist. “This tool was validated which enables us to trust our simulation case, investigations indicated that in some against model tests carried out in our own results. A particular strength of Rolls-Royce is operational modes the blade pass rotational cavitation test facility in Kristinehamn. our ability to combine CFD with testing.” speed was quite close to the natural Conventional design tools could not do this The number of variables explored in frequency of the Azipull, which could because of the influence of the swirl. The the design of the propulsion system and result in vibration and noise. combination of advanced CFD methods, its complexity cannot be understated. The To mitigate this, Rolls-Royce designers validated by cavitation testing at model scale, Savannah has a number of propulsion modes

18 rolls-royce indepth magazine for different operations – boost, high speed, diesel-electric, manoeuvring and stationary. Therefore the control system was designed The well laid out thruster room. to switch between these modes seamlessly, ensuring passengers were not disturbed by any noise and vibration, which sea trials confirmed. Achieving this added significant At the 2016 ShowBoat complexity to both the control system and design awards, Savannah won no less than three associated hydrodynamics, which had to be prestigious awards. clearly understood before the system’s on- board controller could be programmed for optimum performance. “Rolls-Royce is probably the only company that could have developed and produced this ground-breaking system for this innovative vessel,” says Grunditz. “It required an extensive primary research base built up over years, the ability to develop innovative computer design tools, undertake experimental validation and turn the design into a physical reality that could be manufactured, installed and operated.”

For more information email: [email protected]

rolls-royce indepth magazine 19 latest projects Investing in adventure

Norwegian shipping line Hurtigruten has placed its largest ever order for Norway’s Kleven shipyard in Ulsteinvik, up to four new 600-passenger explorer vessels, designed by Rolls-Royce a long-standing partner, has secured the and to be built by Kleven Verft contract to build the vessels. “People no longer want to spend their holidays being passive spectators,” words: richard white engaged in seasonal adventure cruising says Daniel Skjeldam, Hurtigruten CEO. to Svalbard, north of Norway, Iceland, “The new adventure traveller is looking Greenland and in Antarctic waters. They can for authentic experiences, which is why urtigruten, Norway’s world also operate the traditional coastal service. sedentary, standardised travel packages famous coastal shipping line, This year there are now four Hurtigruten are becoming less popular and active H started in 1893 as a service ships engaged in this type of cruising, and adventure travel is booming. We offer real carrying passengers and goods from 2017 the company will offer explorer experiences in local environments, just from Bergen in the south to Kirkenes in the travel to additional new destinations such steps away from wildlife.” far north, providing a vital link to a total of as the Amazon rainforest and Arctic Canada. Rolls-Royce has worked closely with 34 towns and villages along the way. To meet the forecast rise in demand, Hurtigruten and Kleven to develop the It still operates on the same route, but is Hurtigruten is expanding the adventure NVC 2140 design to meet the owner’s now seeing a rising demand for adventure cruising side of the business significantly, tough requirements and the polar tourism, so the trip has become more of with the largest investment in the weather conditions in which the vessels a tourist experience than an economic company’s 120-year history. Rolls-Royce will operate. The new ships are lifeline. One vessel leaves Bergen each day, has signed a contract to design two new designed specifically for adventure- taking 11 days to complete the round trip. Hurtigruten ships for expedition cruising rich expedition voyages in the In recent years, Hurtigruten has extended in polar waters, with options for two more. Arctic and Antarctic regions, as its activities, with several of the newer ships Following an international competition, well as traversing Norway’s long

20 rolls-royce indepth magazine Investing in adventure

“The new adventure traveller is looking for authentic experiences, which is why sedentary, standardised travel packages are becoming less popular and active adventure travel is booming” NVC Daniel Skjeldam, Hurtigruten CEO 2140 rolls-royce indepth magazine 21 latest projects

FROM LEFT TO RIGHT: Helge Gerde, Director, Rolls-Royce; Ståle Rasmussen, CEO, Kleven; Erna Solberg, Norwegian Prime Minister; and Daniel Skjeldam, CEO Hurtigruten at the contract signing.

coastline, and will be equipped with advanced environmentally “Among the deliveries will be the award friendly technology to minimise emissions, underlining winning Unified Bridge, which represents Hurtigruten’s commitment to sustainability. a complete redesign of the ship Guests will be able to attend onboard lectures about the destinations, lead by bridge environment” experts in history, zoology, botany and environmental science. Experienced with a large observation lounge, pool and supply an integrated package of technology expedition teams will accompany saunas. On lower decks will be the main and equipment. Among the deliveries will passengers on educational excursions to restaurant plus several fine dining areas, a be the award winning Unified Bridge, which isolated places only accessible by ships or gym and massage rooms, a shopping zone, represents a complete redesign of the ship smaller boats. Activities will range from a multi-purpose activity centre with lecture bridge environment. Consoles, levers and climbing and kayaking to RIB-boat tours, halls and an immersive science centre. software interfaces will have a common whale and sea eagle safaris. As the new ships will sail very long look and feel, resulting in a comfortable, The new cruise ships will be around distances in the course of a year, some of ergonomic, clutter free and ultimately more 140m long with 23.6m beam and 5.3m it in ice infested waters, both strength and safe and efficient working environment for draught with accommodation and facilities low propulsion power for a given speed are the captain and his team on the bridge. A for passengers and crew spread over required from the hull design, which meets detailed overview of the other equipment nine decks. They will also have a cargo Polar code 6 ice class. The shallow draught selected for these advanced ships and how hold with side port loading for operation will allow access to a wide variety of smaller they will be built will feature in the next on the Hurtigruten Norwegian coastal ports and near shore anchorages. To provide edition of Indepth. service, which can alternatively house a a stable and easily propelled hull form, the The first of these new ships is scheduled fleet of RIB tenders to take passengers patented Rolls-Royce Environship design for delivery during 2018 with the second ashore on expeditions and wildlife principles were used, with a near vertical following a year later. observation excursions. bow and integrated bulb to improve In addition to comfortable performance in a seaway and thereby accommodation for up to 600 passengers enhance passenger comfort. in 300 cabins, plus crew and shore In addition to the innovative ship design For more information email: expedition leaders, there will be a top deck with wave piercing bow, Rolls-Royce will [email protected]

22 rolls-royce indepth magazine NVC 2140 in numbers...

Length (metres) Draught (metres) Passenger capacity

140 5.3 600 Beam (metres) Decks Number of cabins 23.6 9 300

rolls-royce indepth magazine 23 latest projects

The Rolls-Royce-designed and equipped Netstern trawler Holmøy is one of the world’s gain most advanced fishing vessels. It has now entered service with the Norwegian fishing company Prestfjord Havfiske AS, and will be mainly operating in waters around Norway, Russia and Greenland

words: richard white actual operations, allowing the owner and easily propelled hullform. DNV-GL ice ourselves to work together to optimise class has been specified: 1B generally and hull, equipment and propulsion for 1A* on the hull. olmøy is a 69m-long stern Holmøy’s planned operating profile, both The catch is headed, gutted and deep trawler fishing for cod, haddock trawling and transit.” frozen in blocks, loaded on pallets in the H and shrimp. It is the third Comprehensive data from fishing gear packing hold then transferred to the vessel to join the Prestfjord and onboard systems has also allowed the 1,400m refrigerated fish hold. Havfiske fleet of Rolls-Royce design, and crews of Prestfjord to raise the efficiency “We were the first to specify the incorporates a range of new equipment. of their vessel and use health monitoring Rolls-Royce trawl winch with high torque The new trawler’s design has been strongly to plan machinery maintenance based on permanent magnet (PM) motor drive. Also influenced by analysing data from 30,000 condition and trend rather than inflexible the first with the newly introduced Bergen hours of operation of the Rolls-Royce overhauling by time interval. B33:45 diesel engine to go into service, designed Prestfjord, which was built in 2010 Holmøy is an NVC 370 design, developed together with hybrid shaft generator and has 200 sensors on board. using operating experience with Prestfjord. (HSG), shaftline with Promas and Innoduct “This data has been used in several The new trawler is 69.7m long with a propeller, and the Unified Bridge,” says ways,” says Einar Vegsund, Head of Fishing 16m beam and about 5m longer than shipowner Knut Holmøy. “We consider the Vessel Design. “It provides information on its predecessor, giving a slimmer and risk as small, and the technical advance well

24 rolls-royce indepth magazine latest projects

The new 50-tonne pull trawl winch is powered by a compact permanent magnet motor.

MORE ON DiGITAL See a gallery of images from Holmøy on our digital issue, available from iTunes or Google Play

Normally providing all power required on board is Shipowner a 9 cylinder Bergen B33:45 Knut Holmøy diesel rated at 5,400kW.

worth having in terms of both transit and normally provides all power needed on net drum. The trawls are controlled by fishing efficiency. We haven’t experienced board, for trawling, fish freezing and the the Autotrawl system. Holmøy follows any particular teething troubles with the hotel load, with the HSG supplying the the Unified Bridge concept, with layout of new equipment. In fact the process of tuning electricity. Under other conditions Holmøy bridge consoles and controls based on the up Holmøy has been what we would expect can operate in diesel-electric mode using owner’s and skippers’ experience. with a well built vessel with well proven diesel gensets to provide propulsion power “Our new ship is quite a big investment, equipment, rather than equipment that is via the HSG power take in. The Promas but we are confident that the experience new to the market.” system with CP propeller and Innoduct that has gone into the design, the This season Holmøy will fish the Barents nozzle maximises propulsion efficiency, quality of construction and equipment, Sea and the North Sea basin. “Our new trawler while the NVC 370 hull design combines and the technical advances giving fuel has three quotas for fish,” continues Knut excellent seakeeping with low resistance. and emissions savings and improved Holmøy. ”That is enough to keep Holmøy The new 50-tonne pull PM trawl winch efficiency, will make it a good investment,” working year round. We can fish until the hold joins two other AC electric trawl winches concludes Knut Holmøy. is full before returning to port.” handling the double trawl. Other Propulsion machinery comprises a nine Rolls-Royce fishing gear includes eight cylinder 5,400kW Bergen B33:45 engine 20-tonne sweepline winches, eight other For more information email: that produces 500kW per cylinder and auxiliary winches and a 20m-capacity [email protected]

rolls-royce indepth magazine 25 customer focus e f f i c i e n t +

Oncea both of Scandlines’ g new passenger i l vessels are e in service between Denmark and Germany, the choice of Rolls-Royce propulsion system will help to double capacity on a challenging route between Scandinavia and Germany

ABOVE: A centreline words: andrew rice That improvement is due in has taken into account the shallow no small part to the innovative Promas CP propeller, water on the entire 26 nautical mile flanked by two Rolls-Royce propulsion system that Azpull azimuth run. Within Gedser harbour, the F Berlin is the first of two provides the ferries with efficient thrusters, was water depth is only about 7.5m, and new modern passenger propulsion in transit and agile determined to be the depth varies between 14 and 21m and freight hybrid manoeuvring in harbour. the best propulsion over the rest of the route. M ferries to enter service Berlin and its sister can carry solution following Another complicating factor is extensive evaluation this year for the German-Danish 1,300 passengers in considerable and tank testing. the strong across current at the ferry operator Scandlines. comfort and the equivalent of opening between the piers at Gedser. When sister vessel MF 460 cars or 96 trucks. Both were The operating strategy is Copenhagen enters service later this designed specifically for the route therefore to accelerate rapidly to year on the Gedser-Rostock route and feature a centreline CP Promas nine knots astern when leaving between Denmark and Germany, propeller/rudder and two wing Gedser, then turn the vessel once the two new ferries – together with Azipull thrusters. outside the port, proceed to Rostock, additional improvements at the The vessel length of 169.5m with and turn again before entering terminals – will double the transport a draught of 5.5m is optimised for berth stern first. On the return capacity on this vital route between Gedser harbour at the Danish end of trip, the ferries will go ahead from Scandinavia and Europe. the route, and the design of the hull berth to berth. As part of the investment, the ferry piers and ramps have been The new ferries will greatly increase the traffic capacity on the Scandlines route linking Gedser, Denmark with Rostock, Germany. rebuilt at both terminals to reduce © Scandlines turnaround times. Transit speeds that give optimum fuel economy can be adopted for the given departure frequency of 20 departures per day in a fixed two-hour cycle, which means around 19 knots for a 105-minute passage time. This way of operating puts the focus on manoeuvrability and speed, and hence the design of Rolls-Royce propulsion solution. The two wing Azipull azimuth thrusters are in operation at all stages of the voyage, each driven by a 3,500kW electric

26 rolls-royce indepth magazine MORE ON DiGITAL For extra dynamic content, download the digital edition of Indepth from iTunes or Google Play

© Scandlines

motor. They enable large turning BELOW: When the To maximise propulsive efficiency of the hull is dished to give more forces to be exerted on the vessel, ferry Berlin was and reduce cavitation induced clearance over the propeller. As the put into service whether it is stationary or moving. Søren Poulsgaard pressure pulses, the Promas system ships run at speed in shallow waters, When reversing off the berth and Jensen, Scandlines has a five-bladed propeller. cavitation and pressure pulses were out between the harbour piers at CEO, said: “I am The rudder, with a Costa bulb analysed in detail to ensure they met Gedser and dealing with the cross proud of the result and a twisted leading edge, recovers passenger vessel noise criteria. currents, the Azipulls are rotated we can present to swirl energy in the propeller The propulsion system complies our customers. The for full astern thrust to give precise project has had slipstream that would otherwise with Lloyd’s Register Ice Class 1C course keeping and will accelerate its challenges, but be lost, converting it into additional rules, and FEM analysis was used in the ferry from standstill to nine walking around the forward thrust. propeller design, to meet the new knots in less than three shiplengths. ferry, I am happy we The Promas is also a low-drag Finnish/Swedish rules which require remained firm in In transit, the thrusters deliver our decision.” solution in the feathered position, blade strength to be calculated efficient forward thrust. and the five-bladed monoblock against a stated ice loading. For manoeuvring and at lower propellers on the Azipull units are Environmentally friendly power speeds, the centreline CP propeller designed to provide high propulsive for propulsion and hotel load is is feathered. Once the ferry’s speed efficiency up to 17.5 knots. provided by four diesel engines with reaches 17 knots, the propeller is This innovative solution combined scrubbers, one less than a set to the freewheeling pitch and was designed after extensive non-hybrid design, integrated with clutched in. The centre shaftline then mathematical modelling and a 1.5MWh energy storage system of supplies the additional propulsion test tank work, with input from lithium polymer batteries. thrust needed for full transit Scandlines, Rolls-Royce and the test These new ferries now join the speed, driven through a combining tank establishment in Hamburg, Scandlines fleet, which is the largest reduction gearbox. HSVA. Model testing was also fleet of hybrid ferries in the world. Two generator sets, two main undertaken in Duisburg, where The ferries were completed in engines and a battery pack provide a the tank could be configured the Danish shipyard Fayard, and total of 18MW to the propellers and to evaluate performance in represent an investment of more the hotel load. The Helicon X3 control shallow waters. than €140 million (£114m) per vessel. system adjusts propeller pitch and Small underkeel clearance Together with the expansion of speed, and determines the power can give rise to propeller wear the port facilities, the ferries will fed to the azimuth thrusters, to give or damage. To minimise this, complete Scandlines’ strategic the optimum power split of 40 per the thrusters are positioned focus on expanding the central cent of the total equally divided close up under the hull, the and eastern transport corridor between thrusters, and 60 per CP propeller diameter is between the European mainland cent to the centreline controllable limited to 4.6m, and and Scandinavia. pitch propeller. the bottom

rolls-royce indepth magazine 27 customer focus k e e p i n g t h e f i s h f e d The aquaculture industry is a major part of Norway’s economy and farmed salmon is one of the country’s most important exports. LNG-powered vessels are playing a key role in sustainably feeding the fish

words: richard white to Marine Harvest ASA, one of the bunker at the Marine Harvest base biggest names in fish farming, and at Valsneset while we are loading were designed and built to meet fish feed pellets.” ith a coastline of their exacting requirements. On With Harvest, the 125m3 101,000km, Norway has During a typical round trip, each horizontal cylindrical LNG tank is W innumerable cold clear vessel will deliver a total of 3,000 under an enclosure above the cargo fjords and island bays tonnes of feed pellets to between holds. A cabinet on the upper deck that provide ideal growing 15-20 fish farms along the west coast, port side houses the bunkering conditions for farming fish, and one from the feed factory at Valsneset ABOVE: Ivar Ulvan, connections and control valves. of the most popular is salmon. north of Trondheim to as far south who runs the family Bunkering is controlled from a To satisfy the appetites of the as the Ryfylke fjords, near Stavanger. owned shipowner station at the entrance to the growing fish, ships transport feed Indepth recently went on Egil Ulvan Rederi AS forward superstructure, or from that was founded pellets from the factory to the board With Harvest to evaluate in 1919. the engine control room. Both storage bins at the fish farms. the owner and crew’s operating stations have screens showing Shipowner Egil Ulvan Rederi AS experience after a year and a half of system status and gas leakage operates two specialised sister intensive operation, running about alarms. This information vessels dedicated to this business, 6,000 hours a year. includes the flowrate of gas, With Harvest and With Marine, that “With the schedule we are predicted consumption went into service in 2014. The two running now, we usually bunker LNG for a given voyage plan, 70m vessels are powered by Bergen once a week, taking 35-40 tonnes, and the amount of LNG C26:33 nine cylinder gas engines. but this can vary from season remaining in the tank. They are on long-term charter to season,” says Capt Blikø. ”We In addition to the

FISH FACTS • Every day, 38 million meals of Norwegian seafood are eaten worldwide; 12 million come from aquaculture and 11 million are Norwegian salmon meals • A typical fishfarm consists of between six and ten cages holding 3-4,000 tonnes of fish. Cage diameters are usually 50m, as long as an Olympic- size swimming pool Source: Norwegian Seafood Federation

28 rolls-royce indepth magazine main 2,430kW Bergen gas engine potential problem of a lack of LNG that turns a CP propeller through bunkering infrastructure.” a reduction gear and drives a shaft Having made the decision generator, With Harvest has two about LNG, the choice of a Bergen 570kW diesel generators plus a pure gas engine from Rolls-Royce k e e p i n g t h e 100kW harbour set. The variable was quite simple. frequency shaft generator has a “We had already decided that the 1,900kW rating and the machinery dual fuel route didn’t appeal as it can be run in several modes. is a compromise. We also wanted a “We normally run on the Bergen medium speed engine suitable for gas engine at 70 per cent MCR with mechanical drive to the CP propeller the shaft generator supplying the able to handle quick changes in load. electrical loads,” says Capt Blikø. For the power required, the nine “This gives us a service speed of cylinder Bergen C-series gas engine 13 knots. The engine accepts load was the natural choice.” f i s h f e d changes easily, and in practice I’m The feeling is that designing an not conscious that it is a gas engine. LNG installation is more demanding If the weather is really against us than diesel. Rules are strict on and we need maximum power, we ventilation, double pipe systems can start a genset to supply the and gas sensors, leading to extra hotel load, with all the main engine equipment and the odd false alarm output driving the ship. I think this of a gas leak. On the other hand, has only happened once, but if we there is less work in treating and had a main engine shutdown, we in close co-operation with the ABOVE: The compact changing lube oil than in a diesel can use the diesel gensets to feed charterer. Marine Harvest is very and clean engine installation, as the gas engine’s oil room with its single power to the propeller using the aware of environmental impact in nine cylinder Bergen remains clean and in good condition. shaft generator as a power take-in, all its operations, not least the ships. C26:33 gas engine. Bunkering is easy and has proved to which gives us about 9.5 knots. Clean class was specified, indicating be a straightforward operation. “But we don’t use gas and diesel minimum emissions to sea and air. BELOW: The two With Harvest and With Marine fishfeed carriers engines together for propulsion; “Going for LNG was the natural are complex vessels from the cargo operated by Egil the main engine is stopped choice as it significantly reduces Ulvan Rediri are carrying aspect. Each has a capacity and declutched if the diesels CO2 and dramatically cuts NOx, LNG powered and of about 5,000m3, corresponding drive the vessel.” with virtually no SOx emissions. were designed to to about 3,000dwt, and feature Egil Ulvan Rederi AS is a The downside is the increase in meet the stringent a closed loop loading and environmental successful shipowner, founded capital cost due to the LNG tank, requirements of unloading system. in 1919 and now in its fourth gas conditioning plant and safety charterer Marine Feed pellets come in three sizes generation of family ownership. As systems, but this is offset with Harvest. and require careful handling to well as the two specialised fish-feed support from Norway’s NOx fund. prevent them from crumbling. © Egil Ulvan Rederi carriers, the company also owns and “As Marine Harvest already has They are delivered to the ship operates a number of coastal cargo LNG storage for the Valsneset feed through a boom conveyor. Six ships. We asked Ivar Ulvan, who runs pellet factory, that was available holds allow different sizes to the company, about the background for bunkering. Therefore our two be kept separate. to building With Harvest and its ships can bunker efficiently for the sister With Marine. planned trip while loading cargo, For more information email: “We developed the vessel design saving time. We therefore avoid the [email protected]

rolls-royce indepth magazine 29 customer focus a d e ca d e o f n ava l

sWhat started u out little pmore than p ten years oago as a small rt team providing in-service support to the Royal Australian Navy’s amphibious fleet has evolved to become one of the naval sector’s leading fully integrated material support providers

words: patrik wheater Department of Defence (DoD). improve the through-life maintenance, Rob Madders, Programme Director at logistics and technical ship management RRAS, takes up the story. “There’s been a of four RAN vessels: the replenishment oiler ogether with strategic Rolls-Royce presence in Australia since HMAS Success, the amphibious landing ships, partner Kellogg Brown & Root 1999, but it was in 2006, following the HMAS Tobruk, HMAS Manoora and HMAS T (KBR), Rolls-Royce Australia expansion of our 50/50 partnership with Kanimbla. A key aspect of the agreement Services (RRAS) now has a KBR, that our position as an organisation was to manage equipment obsolescence, fully integrated team of more than 100 capable of minimising naval maintenance identify upkeep requirements and establish naval engineering specialists operating costs and improving a vessel’s operational equipment and maintenance baselines, a from a state-of-the art facility inside Royal availability was cemented.” complex task as some of the vessels were Australian Navy’s (RAN) Garden Island The Rolls-Royce and KBR team secured commissioned 30 years earlier. naval base, in Sydney, providing critical a long-term fully integrated materials “In essence, this meant itemising every engineering support to the Australian support (FICMS) contract. Its aim was to piece of equipment and component installed

HMAS Adelaide is one of two LHDs supported by the Rolls-Royce and KBR team. All images: © Commonwealth of Australia

30 rolls-royce indepth magazine at the new-build stage, along with any the largest vessels in the RAN fleet. A third subsequent changes made during refits vessel, the LSD (Landing Ship Dock) HMAS before we could confirm the current status of Together, Rolls-Royce Choules has recently been added to the list. a d e ca d e o f n ava l the vessels and improve their maintenance and KBR have the “We have grown to become one of the baselines,” recalls Madders. leading FICMS providers to the Australian Hitherto, the RAN had operated a largely breadth of capabilities Department of Defence,” says Madders. reactive maintenance programme, so a move and teaming “Together, Rolls-Royce and KBR have the to more prescriptive planning was needed. breadth of capabilities and teaming However, in order to provide a platform experience to deliver experience to deliver the world-leading from which the DoD could manage vessel the world-leading integrated material support demanded costs more effectively and concentrate on not only by the RAN, but also other navies operating their ships at sea, RRAS had to integrated material around the world.” document each vessel’s base material state support The potential for RRAS to roll out this before it could ‘rebuild’ and implement integrated support model to navies outside planned maintenance schedules. Australia is not lost on Sam Cameron, The identification, validation and In older vessels, structural degradation SVP Sales and Business Development. “If verification process – part of a wider Control makes up a significant proportion of upkeep other navies want to separate the means Data Remediation Project to increase the expenditure and budget growth, if an of production from the identification operational lifetime of the vessels – was adequate survey regime is not in place. requirement, then Rolls-Royce can transfer “an administrative challenge taking two “Structural defects result in significant the model across to other nations. It years to complete,” says Madders. “The data investment in steel renewals, but our has been very successful because quite required to upkeep a vessel in service is more planned survey regime has reduced this simply there are no vested interests. The extensive than the ILS (integrated logistic substantially,” says Madders, going on to only way navies can reduce the cost of support) data produced at the new-build explain that RRAS was able to keep budget ownership, the cost of maintenance and stage. It is inadequate and not extensive growth under 12 per cent during the vessels’ reduce operational costs is by separating enough to sustain a vessel during its 2015/2016 refits. “This was unprecedented for the identification of a problem from operational phase. We needed to take each these vessels,” he attests. the solution.” vessel back, so to speak, to the design and The success of the FICMS contract signed build stage to ensure everything is baselined in 2006 and the ensuing maintenance cost and any subsequent changes are correctly reductions achieved for the vessels, three documented – machinery, components, of which have now paid off, resulted in the controls, software updates, everything. RRAS/KBR partnership winning the bid to “We also introduced a hull survey regime, provide similar FICMS to amphibious assault bringing in specialist naval surveyors to ships HMAS Canberra and HMAS Adelaide, For more information email: assess the vessels for any structural defects. two 26,000t LHDs (Landing Helicopter Dock), [email protected]

rolls-royce indepth magazine 31 latest technology

Reduction of Improvement life cycle Risk sharing of safety, cost of the and predictable availability and equipment cost performance

r ea s s e s s YOUR RISK words: simon kirby With the expansion of its marine “Power by the Hour” service, Rolls-Royce plans to arco Cristoforo Camporeale is on a revolutionise the way its customers do business, mission. “We want to M change today’s business by reducing the risk and the cost associated model fundamentally,” declares the with operating and maintaining its equipment General Manager, Health Management Solutions. “We want planning; remote assistance, and ABOVE: Through much as 25 per cent over a 10 to our customer to outsource their the capabilities of a global service services such 15-year contract,” says Camporeale. as remote maintenance – and the risk that infrastructure to provide timely “That’s while improving the overall assistance and goes with it – to us. Let us worry preventive maintenance. fleet monitoring, availability, performance and safety about what needs to be done, and With the Power by the Hour model, Rolls-Royce can help of our products.” when. Then customers can focus on operators’ maintenance costs can be operators reduce The starting point is asset generating the maximum revenue lower, as payment is only made for the their costs. monitoring. This gives the earliest from their operations.” time the assets are operating. There possible warning when things Rolls-Royce can do this by is less need for operators to maintain start to go wrong. Sensors are combining four key elements: their own service infrastructure. part of a web of devices gathering asset and fleet monitoring; “A Power by the Hour plan data from all the vessel’s dynamic equipment maintenance could cut customers’ costs by as Rolls-Royce equipment.

32 rolls-royce indepth magazine The information collected Class Society approvals are is transmitted back to a data Four key elements changing to reflect the reality of centre. For aircraft, Rolls-Royce has asset monitoring. These approvals pioneered an approach to identify to reduce your risk EDGE mean that when regular equipment and process only the most important COMPUTING surveys are undertaken, the data can engine data on wing, and securely Rolls-Royce uses be reviewed to determine the actual transmit it back to ground, so any ‘edge computing’ condition of the equipment, without techniques to immediate actions can be taken. This optimise what data the need for time-consuming exploits the available bandwidth is processed and internal and visual inspections. to best effect. The remaining data analysed close to Should an identified fault be is analysed later – at the end of the the asset (on board) serious a Rolls-Royce engineer, with and what data voyage – when connectivity is better. needs to be sent the permission of the Master, can to the Rolls-Royce remotely enter the vessel’s network REMOTE RESCUE service data centre. and remotely assist the crew to Advanced manage or fix the problem. When the dynamic positioning system patented predictive on subsea construction vessel Far analytics are Sleipner stopped working off the coast applied to fuse FORWARD THINKING West Africa, the stakes were high. Vessel data and create In September 2015, the Eidesvik multi- Attempts by the crew and Rolls-Royce monitoring diagnostic networks, purpose offshore vessel Viking Poseidon engineers on the phone could not rectify significantly was making a 24-day voyage back to the issue. Fortunately, the vessel is fitted reducing false Norway from the US. with the Rolls-Royce Acon Connect – alerts while giving Eidesvik had asked the Rolls-Royce Remote Access System. This meant a advance warning data centre in Finland to keep an eye on skilled Rolls-Royce software engineer of problems or a previously identified thruster fault. based in Norway could log on to the possible failures. Fifteen days into the voyage, the service vessel and help. The challenge team contacted the vessel. Unknown Once the captain had given with trend and to the crew – there were no vibrations, permission and switched on the condition-based smell or heat detected – significant connection from the bridge – an monitoring is changes in vibration levels were being essential security precaution – the to balance the picked up, and it was now impossible to engineer was able to establish a secure prediction of real predict how long the bearing would last. encrypted link, explore the ship’s failures against the Communication between the systems, then identify and fix the risk of false alerts, shore-based team and the crew was problem. In the past, this would have which generate established and remedial actions taken. required flying the engineer to the unnecessary Left unaddressed, the thruster could ship and significant disruption to the maintenance Remote have suffered a major failure, costing its vessel’s schedule. activity and costs. owner time and money. Instead, a new assistance Rolls-Royce bearing was ordered and sent to the has developed quay to await the vessel’s arrival. olls-Royce is also an approach to harnessing the data predictive analytics accumulated over years that combines lots ach vessel covered R of different data of monitoring marine points with known by a Power by the Hour equipment. This provides the detail failure models. agreement will have a about reliability, life expectancy and This allows the E single Project Manager failure modes, so there is a deep probability of failure responsible for administering all understanding of when products are to be predicted with aspects of the agreed maintenance more than 93 per deviating from normal behaviour. cent confidence and plan and the health of the This knowledge and the use of early enough for equipment. Depending on the advanced analytic techniques will operators to take contract, the customer will get a also be crucial in the development of preventative action. periodic invoice and Rolls-Royce will remote and autonomous ships. Dynamic maintenance take care of everything else. Therefore, Rolls-Royce can tailor a planning Power by the Hour has been base ‘equipment maintenance plan’ available to aerospace customers to a customer’s planned operation. for nearly 20 years. However, this For example, if the life of a key piece of year it will be on offer across the BELOW: equipment is five years, preventative Marco marine sector. To help customers maintenance is scheduled for four Camporeale move to the new business model, years and 10 months, so operations Rolls-Royce will install the necessary are not disrupted. This is the first sensing and analytic equipment to step towards cost saving. deliver the service with no additional However, real-life operations up-front costs. The customer pays can be different. Rolls-Royce Power a fixed fee for the duration of the by the Hour services can compare contract, making maintenance real vessel day-to-day operation costs predictable. with its actual operating profile and alter maintenance schedules Send an email to dynamically, potentially increasing Intelligent Marco_Cristoforo.Camporeale@marine. vessel availability. field service rolls-royce.com

rolls-royce indepth magazine 33 latest technology TRIED AND

TESTEDThe new MTU marine gas engine has completed 3,000 hours of bench testing, confirming its excellent performance, environmentally friendly characteristics and reliability

words: silke rockenstein

ow that its new MTU marine gas engine has completed N 3,000 hours of bench testing in Germany, Rolls-Royce is prepared to deliver its first certified series production high-speed gas engines for commercial vessels in 2018. “We can confirm that the engine meets both our requirements and those of our customers,” said Dr Ulrich Dohle, CEO, Rolls- Royce Power Systems AG. “Its performance and its acceleration behaviour are similar to the excellent characteristics of a diesel engine. It is economical, reliable and clean.”

16v 4000 – up to 2,000kw The 16-cylinder MTU gas engine will cover the power range from 1,500 to 2,000kW and will be based on MTU’s proven 16V 4000 M63 diesel engine for workboats. As of the end of 2017, the first engines will be used to power a tug built by Damen for Svitzer towage and salvage company. The two companies have entered into a collaboration with MTU to jointly put the world’s first tug supplemented by an eight-cylinder engine, low emissions and improved economy while powered by high-speed gas engines into which will be available on the market with a delivering the customary high performance. service. It will feature high performance in power range of 750 to 1,000kW. addition to reduced fuel costs and emissions. As of 2019, this MTU gas engine is to Development focus As a result of their dynamic acceleration provide the propulsion for a new Lake The new MTU gas engines will be equipped behaviour, their low environmental impact, Constance car and passenger ferry operated with a multipoint gas injection system, a reliability and economy, the new MTU gas by the local public utility, Stadtwerke dynamic motor management system and engines are ideally suited to tugs, ferries, Konstanz. It will connect the two Lake an advanced turbocharger. The multipoint push boats, and special purpose vessels like Constance towns of Constance and gas injection system is designed to provide research vessels. Meersburg, a distance of 7km that takes the engine’s dynamic acceleration behaviour, around 15 minutes. The new ferry will be increased performance and reduced 8V 4000 – up to 1,000kw one of the first in Europe to be powered by emissions. This ensures that IMO Tier III The gas engine portfolio will initially be a high-speed pure gas engine. It will feature emissions standards are met without the

34 rolls-royce indepth magazine S4000 GAS ENGINE FOR MARINE APPLICATION

Multipoint gas injection valves MPI-valves provide high 1 flexibility to influence the air/gas mixture related to: • Start of injection 2 • Gas rail pressure.

1. Electromagnetic MPI valve 3 2. Air mixing device 4 3. Gas rail 4. Outer barrier 5 5. Air manifold

Key requirements and achievement

Performance range diesel vs. gas engine 14,000 16V 4000 M65-N gas 22

12,000 20 2,200 kW 18 10,000 2,000 kW 16 16V 4000 M63 MTU diesel 1,800 kW 14 8,000 1,600 kW 1,400 kW 12

6,000 1,200 kW 10

1,000 kW BMEP [bar] Torque [Nm] Torque 8 4,000 800 kW 6 600 kW 4 2,000 400 kW 200 kW 2

0 0 600 800 1,000 1,200 1,400 1,600 1,800 2,000 Engine speed [rpm]

Transient engine behaviour – gas vs. diesel

The load 2000 kW @1800 rpm acceptance Identical performance characteristics of the S4000 gas engine is comparable to today’s Acceleration diesel engine Acceleration gas engine S4000 M63 [bar]pressure Mean effective diesel engine Time (s)

the gas engine leaves nothing to be desired in terms of the customary reliability of a “It was possible to simulate real-life proven MTU Series 4000 diesel engine. manoeuvres, which represent the dynamic In its development of the new marine gas engine, MTU has benefited from the 30 years’ acceleration of a diesel engine” experience it has gained with stationary gas engines for power generation, and the need for additional exhaust after treatment. safety precautions are required in the experience available from Rolls-Royce, which Controlled combustion ensures that engine room. On the test bench it was has supplied medium speed Bergen pure fuel is used efficiently. The safety concept, possible to simulate real-life manoeuvres, gas engines for some 10 years. which has been optimised for gas operation, which represent the dynamic acceleration of includes double-walled gas supply lines, a diesel engine. The successful completion More information at which means that no additional complex of 3,000 hours testing demonstrates that www.mtu-report.com/Marine/SMM2016

rolls-royce indepth magazine 35 latest technology

As the move to electric equipment on board continues to advance, Rolls-Royce has integrated next-generation permanent magnet (PM) motor technology into its tug escort winch range, giving tug operators dynamic performance, more precise control and safer operations i co n t r o l

the ship. This force has to be applied carefully, as a snapped towline could easily make a bad situation even worse. A second escort mode is ‘dynamic ship assist’, where the tug positions itself to act as an additional rudder. When operating in indirect mode, with the tug being dragged diagonally through the water to steer and brake the tanker, towline forces and brake loads on the winch may be far higher than the tug’s nominal bollard pull. All this places great demands on the tug’s escort winch, and Rolls- Royce supplies a range of specialised winches for this application. Up words richard white tugs. Since the 1990s, oil and gas ABOVE: Escort and to now, they have been mainly terminals have adopted escort towing winches hydraulically driven, but electric towing of tankers to improve their powered by PM drive winches are also offered. The electric motors are oday’s ship-assist tugs safety cases, reducing the risk of simple to integrate range has recently been updated are a closely integrated tankers running aground due to with a tug’s hybrid with the escort winches benefiting combination of hull loss of power or steering in the propulsion system. from the introduction of the new T configuration, approaches to terminals. Rolls-Royce permanent magnet (PM) propulsion system and winches, with In a routine escorting operation motor technology. MORE performance demands particularly the tug runs behind the ship being ON DiGITAL The PM motor gives a high torque strict for escort tugs. Other types of escorted, connected by a towline For extra at low speeds. This means that only dynamic tug focus more on long-distance but not interfering with the content, a small reduction ratio is needed in towing, or emergency towing and ship’s steering. If informed of an download the the gearbox, leading to a low system digital edition pollution prevention. emergency on the ship, such as loss of Indepth inertia, which in turn provides A general increase in ship sizes of steering, the tug acts immediately from iTunes or excellent dynamic performance Google Play has called for increased pulling to provide force in the direction and response, important in escort and pushing forces for harbour required to steer and probably stop and other types of tug work.

36 rolls-royce indepth magazine Using the TX140 PM motor means ABOVE: A tug operator will normally have a direct mounted on the foredeck. The other a smaller winch footprint and also undertaking sightline to the winch, towline main type is the tractor tug typically performance trials. simplifies the winch, eliminating BELOW: A display and ship being assisted. A display using cycloidal propulsion under several components that are subject panel clearly panel clearly shows the towline the bow. Here the escort winch is to wear and need maintenance. shows the towline tension, the length of line out and placed at the stern. The PM escort winch is rated at tension, the length the speed of hauling or rendering. For other towing operations 100-150 tonnes, with great dynamic of line out and the It also provides monitoring of Rolls-Royce provides a wide range of speed of hauling or sensitivity and a line speed up to rendering. the quick release function, winch winches of different configurations 180m/min. With energy saving very mode settings, power pack and sizes. They typically have a large much in focus, the PM winch has the monitoring and alarms. line capacity and the focus is on regenerative capacity to feed up to Where the escort winch is placed pull and brake load and accurate 1,100kW of rendering energy back depends on the type of tug. For spooling. Single drum, double drum into the tug’s network, if the vessel’s azimuth stern drive tugs which are and waterfall types are supplied to electrical system is designed to propelled by twin azimuth thrusters suit the requirements with a choice accept it. Integrated in the compact under the stern, a type for which of hydraulic or electric drive and gear-case module at the opposite Rolls-Royce US-series thrusters are either on/off or adjustable force end to the motor is a friction clutch, much favoured, the escort winch is brakes. High torque motors plug into which allows the operator to release the gear case and pipes and valves the load in less than three seconds have been replaced by valve blocks, in an emergency. reducing the number of components Hydraulic escort winches have and risk of oil leakage. Power for single or double drums and can be hydraulic winches can be supplied specified with anchor chainwheels either from engine PTOs or separate and warping ends. The key point powerpacks. Higher rope speeds are is sensitive operation. Towline can now available in both directions. be paid out or hauled in under full Towing winches range from small control without the line going slack single drum units up to 50 tonnes using the auto-tension system. pull to the specialised anchor- Recovery force is adjustable in the handling and towing winches with range of 0-120 tonnes, and rendering up to 600 tonnes pull. force adjustable from 0-175 tonnes. The powerful brake can hold 420 For more information email: tonnes. In the wheelhouse the [email protected]

rolls-royce indepth magazine 37 round up

PeopleThe Rolls-Royce team

Commissioning the first of a new vessel staying off the customer’s critical our equipment. It was almost design is a challenge, but when that vessel is path. Because we had a thorough flawless. Most of my sea stories from introducing a number of new and emerging understanding of the whole system, trials begin with: “I was eating an technologies, it is the culmination of many we were able to adjust quickly and ice-cream cone in the CPO’s mess accomplish work when a window of when…” That’s not to say it was a years of hard work. Indepth talks to Alex time opened up. We made it our goal pleasure cruise, but it’s a testament Greve, one of the Rolls-Royce engineers on for shipboard testing never to be to the fact that our equipment did the US Navy’s first Zumwalt-class destroyer, awaiting generator set availability, what it was supposed to do all the commissioned earlier this year so we sometimes found ourselves time. An uneventful sea trial is the ahead of pace awaiting completion product of months of long days and of shipside system. hard work. One captain aboard the meet alex greve first sea trial said: “Those ATGs [the What was the most important part RR4500s] really deliver the mail.” in the commissioning for you? It was both the planning and the Which day was the most challenging? How did you feel when you boarded responsiveness to issues as they A couple of times I was asked Zumwalt for the first time? arose. We used the months-long to assess an event from our I felt a sense of great pride. The dockside trials to de-risk sea trials. If equipment’s perspective that the shipyard engineers and technicians, a test produced unexpected results electrical engineers were puzzled as well as our US Navy customer, due to an integration issue with about. As we had comprehensive have expressed a lot of respect for the ship, we immediately engaged data acquisition running all the our product, so it felt great to walk the customer to understand and time, they often came to us to help on the most advanced US Navy ship rectify it – even if the root cause them understand a system level ever built knowing that our products was outside our equipment. It’s event if a test did not go as expected. were going to bring it to life in the been described many times now These occasions were particularly coming months as they powered how smoothly sea trials went for challenging, as there was just me the whole ship. I also felt honoured and a colleague in the middle of the to be on the frontline witnessing ocean with no line ‘home’. There’s the culmination of decades of hard nothing quite like trying to assess work by the Rolls-Royce team that data with a room full of highly- came before me. experienced Navy engineers looking over your shoulder! How did you plan the activities? We leveraged our experience Did you enjoy it? from factory commissioning and I enjoyed the experience immensely. first article testing to develop a It was an incredible opportunity to comprehensive work breakdown participate in commissioning a true structure that we integrated with engineering marvel. I will be telling the customer’s schedule. We were stories of this part of my career for confident in our scope of work the rest of my life. to achieve a safe and successful shipboard GLO (Generator Light- off), so the challenge for us was identifying and communicating “I have just transitioned out of the role as Lead Engineer – DDG1000, into a dependencies in the schedule, broader role within the Marine North which were beyond our control. America Naval Engineering group as the We knew our work would be ‘high Lead Project Engineer. Our project engineers visibility’ on this first-of-class, so are the customers’ primary technical point of contact for US Navy gas turbine products managing our work scope within and have responsibility for managing the a dynamic schedule was essential. engineering scope of work for new and The Rolls-Royce team did a great job existing US naval products.”

38 rolls-royce indepth magazine round up

MORE ON DiGITAL For extra dynamic content, download the digital edition Wherever your vessel is located, Rolls-Royce is not far away of Indepth from iTunes or Places Google Play

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      Tug delivery Bergen breakthrough Remote assistance MTU speed record Thrusters begin delivery New fast ferry Harley Marine in San First Bergen B33:45 in- DP system on one of the Monte Carlo to Venice The US ARC 0.8 azimuth Fast ferry Hai Qin starts Pedro, US, takes delivery line nine cylinder diesel world’s most advanced speed record set by thrusters for Norwegian operating for the Zhuhai of the first two of five engine at sea powering subsea construction 18m SAR vessel in Arctic research vessel High Speed Passenger new tugs and invests the advanced 69.7m stern vessels stops working 22 hours 5 minutes FF Kronprins Haakon Ferry Company between in tailored azimuth trawler Holmøy, which is off the coast of West at an average speed of begin delivery voyage to Hong Kong and Jinguzhou. thruster training for an NVC 370 design. Africa. As the vessel is 52.3 knots, powered by Fincantieri in Italy. It is powered by MTU crews, focusing on safety fitted with Acon Connect two MTU 10V2000 diesels driving Kamewa and optimising vessel technology, engineers engines. New record for Steel Series S71-4 waterjets. performance. in Norway establish an round Italy voyage. encrypted link, identify and fix the problem.

Further  Houston, tel:    

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rolls-royce indepth magazine 39 rolls-royce.com

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