WÄRTSILÄ TECHNICAL JOURNAL
f o u r7. 01
Twenty 2018
COVER STORY
TESTING THE LIMITS 22 Wärtsilä’s newest engine page and its ground-breaking new design
ENERGY 4 Selecting the right 12 The future of LNG tech energy storage We help you evaluate the different Navigate the complex field LNG terminal platforms of energy storage
MARINE 24 Turning emissions 32 Improving thruster into fuel efficiency A new system that converts Creating more effective lost oil into fuel thrust using less fuel in detail issue no. 01.2018 WÄRTSILÄ TECHNICAL JOURNAL | WWW.WARTSILA.COM
Contents WÄRTSILÄ HEADS TO A SMART AND SUSTAINABLE FUTURE
ENERGY Many industries are embracing connectivity and collaboration – LNG terminals – land-based vs. floating including at sea. Wärtsilä’s Smart Marine Ecosystem vision is to storage and regasification technology ...... 4 make shipping intelligent by connecting smart vessels with smart Natural gas takes the role as backup fuel ...... 8 ports. Although the future is always somewhat unmapped, the direction is clear. Hence, Wärtsilä recently acquired Transas, a global Next-generation energy storage systems . . . . . 12 market leader in marine navigation solutions. Bright prospects for Wärtsilä’s Wärtsilä is taking concrete and tangible steps towards smart solar energy strategy ...... 18 shipping, and the acquisition is in line with our Smart Marine Ecosystem vision and strategy. Our product portfolio is the Wärtsilä 31SG, the world’s most biggest in the marine industry, and now the solutions we can offer efficient 4-stroke engine ...... 22 with Transas will further increase the cost-efficiency and eco- friendliness of our customers’ vessels. Taking the environment into account is not just words on paper MARINE for Wärtsilä. In this issue, you can read how Wärtsilä’s Voyage Wärtsilä Voyage Emission Reduction Emission Reduction (VER) (page 24) system helps reduce volatile system turns emissions into fuel ...... 24 organic compound emissions on vessels. On a Very Large Crude Carrier, the system can prevent the loss of up to 270 tonnes of Wärtsilä 20 – Small changes, big results . . . . . 30 cargo a week, all the while helping protect the environment from Wärtsilä’s new retractable thruster is potentially harmful emissions. It makes financial sense, too: the an improvement across all parameters ...... 32 solution spells potential annual savings of up to USD 2 million. Things like the aforementioned acquisition as well as VER are Eco-friendly tugs make a splash...... 36 perfect fits for our overall purpose: enabling sustainable societies Modularisation hand in hand with with smart technology. Smart and sustainable often go hand in manufacturability ...... 40 hand, complementing instead of contradicting each other. MAKING WAVES Wärtsilä’s approach acknowledges players of all shapes and sizes, and the Smart Marine Ecosystem is keen to invite new innovations on A new breed of eco-friendly tugs is SERVICES board. As part of our digital transformation, we’ve established a new helping improve sustainability. Wärtsilä EnergoFlow boosts venture model, including a programme called SparkUp Challenge. The theme of the first round was marine technology, and at the propulsion efficiency ...... 44 end of February, 2 out of 11 finalists were announced as winners after a day full of pitching (page 48). SparkUp Challenge is one of the FUTURE building blocks of Wärtsilä’s ecosystem as well as a key contributor to our Smart Marine vision. The next challenge will revolve around SparkUp Challenge invites start-ups to Smart Energy, again looking to bring together smart and sustainable innovate and co-create together with Wärtsilä . . 48 business opportunities. In the world of rapidly evolving technology, the only constant is iPad change. At Wärtsilä, we’re at the forefront of digital transformation THIS ISSUE OF IN DETAIL is also available on iPad as a in the marine and energy industries Wärtsilä iPublication app from Apple's Appstore, as well as in a browsable web version at www.twentyfour7magazine.com. – but we can’t do it alone. In order to Web build a complete ecosystem, we need a The perfect Embracing Taking network of partners and collaborators. backup fuel? modular product propulsion to Together, we can not only serve our Publisher: Wärtsilä Corporation, John Stenbergin ranta 2, customers better, but also better architecture the next level P.O. Box 196, FIN-00531 Helsinki, Finland | the world by looking after our shared Natural gas, which has a small A design process based on Wärtsilä’s EnergoFlow Editor-in-Chief: Ilari Kallio | Managing editor and editorial office: Virva Äimälä | environment and giving it the care it footprint, may be the right modularisation will increase reduces rotational losses Editorial team: Marit Holmlund-Sund, Mari Kankaanranta, deserves. choice when a large amount of efficiency, reduce production in propulsion systems, Dan Pettersson, Mirja-Maija Santala, Sanni Suominen, Mikaela Terhi fuel is needed. time and improve reliability. boosting efficiency. and Minna Timo l | Layout and production: Spoon | Printed: April 2018 by PunaMusta, Joensuu, Finland ISSN 1797- Ilari Kallio 0032 | Copyright © 2018 Wärtsilä Corporation | Director, Digitalisation Paper: cover LumiSilk 250g/m², inside pages UPM Fine 120 g/m² Wärtsilä Marine Power Solutions E-mail and feedback: [email protected] Editor-in-Chief of In Detail MORE ON PAGE 8 MORE ON PAGE 40 MORE ON PAGE 44
Cover photo: Wärtsilä
in detail [ ENERGY / IN DETAIL ] WÄRTSILÄ TECHNICAL JOURNAL 01.2018 LNG Terminal Comparison Historical concepts (mooring systems and layouts)
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FSRU FSRU FSRU FSRU
/ IN DETAIL ENERGY Jetty Head + Jetty Trestle Jetty Head [ STL Buoy Yoke system
Fig. 1 - LNG terminal comparison. Historical concepts (mooring systems and layouts).
LNG Terminals Worldwide Locations
1 © Wärtsilä INTERNAL 28.3.2018 Jens Norrgård
LNG terminals – land-based
FSRU vs. floating storage and FSU regasification technology Onshore terminal (not all of them)
© Wärtsilä INTERNAL Jens Norrgård Fig. 2 - LNG terminals worldwide. AUTHOR: Jens Norrgård, General Manager, Sales Proposals, LNG Solutions, Wärtsilä Energy Solutions mail: [email protected]
The FSRU concept tanker truck loading systems, which may the units with multiple locations when there The most common concept for FSRUs is be of importance in certain markets and are seasonal send-out needs. (Figure 2) One often reads or hears people say that History Looking at the installed FSRUs today, mooring at shore (> 60% have jetty + access infrastructure systems. The majority of floating storage and regasification units Floating storage and regasification units most of them have a good reason for being trestle). This is the conventional FSRU and the FSRUs are also located onshore, so CAPEX vs. OPEX (FSRUs) are more economical solutions (FSRUs) as a concept were developed in developed: some are political, while some commonly referred to when comparing with the functionalities given could be adapted What favours floating solutions is the compared to land-based terminals. What 2005, driven by the need for a fast delivery are based on location, schedule, public land-based terminals. There are also concepts also to the FSRUs if there was a need for upfront investment, unlike the case in a is the basis for such a statement? Is it LNG storage and regasification solution. safety or environmental constraints. These that use other kinds of mooring technology. modifications in the existing infrastructure. land-based solution. Financing is key to accurate? To answer that question, one The first FSRU was not a new-built unit factors have been the determining factors These are, generally, more expensive systems The most common FSRU concepts are success when comparing with the use of needs a short history lesson to understand but a conversion of an existing LNG carrier for the selection of FSRUs versus land-based that are used where conventional jetty single-purpose terminals with a national chartered units where it will be on OPEX. the past. (LNGC) by a shipyard. The concept was a LNG terminals. So, can one say that FSRUs structures are impractical to construct or are pipeline gas supply or large-scale power Currently (March 2018), the charter rate success, and more projects were developed. compete with land-based solutions? No, not not permitted. generation. for an FSRU is USD 80,000–120,000 per These first FSRU projects had a short really; they are more a complement to each In general, land-based LNG terminals That said, developing a project with FSRU day depending on time charter period, delivery time in comparison with land- other, since the projects are very different. are more multifunctional terminals, technology limits one to a fixed storage location and size. This easily adds up to based terminals, which was the main driver. The values FSRUs bring to the LNG value since they also have LNG onshore. These volume and send-out volumes suitable for MUSD 29.2–47.5 on an annual basis. This Simultaneously land-based terminals were chain are not the same that land-based functionalities might be reloading of LNG a national pipeline. However, flexibility can is for the charter, e.g., the FSRU, insurance, built for long-term operations. terminals do. (Figure 1) feeders, bunkering of vessels and LNG be achieved if there is a possibility of sharing crew and maintenance, and on top of this 4 in detail in detail 5 [ ENERGY / IN DETAIL ] WÄRTSILÄ TECHNICAL JOURNAL 01.2018
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Lifecycle costs 0 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 Millions
-200 Daily equivalent costs
-400 160 000 150 000 / IN DETAIL ENERGY [ 140 000 -600 Process costs 130 000 120 000 -800 110 000 Process costs 100 000 Cumulative CAPEX and OPEX (USD)
90 000 -1 000 80 000 Charter rate Process costs USD Process costs 70 000 -1 200 60 000 Years 50 000 40 000 Onshore terminal FSRU (60 000 USD/day) FSRU (80 000 USD/day) FSRU (100 000 USD/day) FSRU (120 000 USD/day) 30 000 Charter rate 20 000 Charter rate 10 000 0 Land-based terminal FSRU FSU + JRU FSU + FSRB Fig. 4 - Lifecycle cost comparison of FSRU, FSU and land-based terminal.
Fig. 3 - Daily equivalent costs.
Concepts
come the regasification costs. Depending The cost of an engineering, procurement By adding a small power plant to the on regasification technology (sea water / and construction (EPC) project of course concept, we conveniently solve the boil- glycol or steam system) and capacity, we depends on many parameters, everything off gas management during low send-out Typical FSRU Project Typical FSU Project Different FSU Project need to add another USD 15,000–25,000 from send-out capacity and storage size periods or seasonal periods by generating per day for a 300–500 MMSCFD send-out to location (bathymetry and met-ocean electricity for the grid. The waste heat from regasification system. conditions). Assuming a typical location the power plant cooling system can be LNGC FSRU LNGC FSU LNGC / FSU Gas pipeline During the last few years, another representing a majority of the FSRUs, e.g., used for LNG evaporation, e.g., increasing LNG Gas LNG (truck loading) JRU Gas pipeline comparable system, a floating storage unit on shore at a jetty head, we can compare the the overall efficiency of the installation. pipeline pipeline (FSU), has been used in several projects. CAPEX and OPEX costs of floating versus (Figure 5)
These units are equipped only for storage. land-based LNG terminals. Power Plant How to select technology • boil off gas management The regasification system is installed either Studying the CAPEX and OPEX (see (= producing electricity) on a jetty, on a separate floating storage Figure 4) shows the cumulative cost over a How does one make the selection for an • Waste heat (= for LNG FSRB evaporation) regasification barge (FSRB) or on a land-based 20-year period (assumed project lifetime) LNG terminal technology? In general, • Storage capacity during FSU/LNGC under voyage terminal. The fact that idle LNGCs are available with various technologies. As can be seen one can say if the project lifetime is more • Re-gasification of LNG in the market now enables faster delivery of from the graph, the breakeven is about six than 10 years, it is more economical to these projects. However, conventional LNGCs to seven years for FSRUs versus land-based use a land-based solution. Other selection (also known as “old ladies”) are currently based terminals. (Figure 4) criteria would be the need for fuel on charter rates of USD 25,000–40,000 per What is interesting is combining an FSU diversity, permanent asset and operational day, and when it comes time to replace the (and also using the FSU as a carrier) with availability/reliability and financing. Fig. 5 - Concepts.
LNGC, there’s no telling what the charter rate an FSRB that is used as a buffer storage The storage volumes and regasification 1 © Wärtsilä INTERNAL 29.3.2018 Jens Norrgård would be. (Figure 3) while the FSU is on voyage. This is a good volumes of land-based solutions can also When constructing a land-based concept, since you have the regasification more easily be expanded if needed, with terminal, one does not have any charter on board the FSRB and the concept is easily the assumption that land area will be costs for storage and regasification, since deployable for other locations. This can also available. the costs of this functionality are part of the be used as an intermediate solution during CAPEX cost of the terminal. the construction of a permanent asset. 6 in detail in detail 7 [ ENERGY / IN DETAIL ] WÄRTSILÄ TECHNICAL JOURNAL 01.2018
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Fig. 1 - The relative volumes of one unit of natural gas in different states.
The choices available for storing natural roads and at a short distance from an CNG/ short outages of pipeline gas are expected gas are limited, particularly for small-scale LNG plant, the easiest way to get gas is by and the time between these are long, the solutions. We either need to compress the using a truck loading system that supplies capacity of the liquefaction system can be gas to compressed natural gas (CNG) or CNG/LNG. If the plant is located far away small (and cost-efficient) and the storage liquefy to liquefied natural gas (LNG). For both from the coastline and its closest can be bigger to give a longer backup time. large-scale solutions, on the other hand, CNG/LNG facility, other means should be Figure 1 shows the relative volume of gas there are other solutions available. Pumping considered. in different storage solutions. The figure gas in under bedrock or salt formations is Using pipeline gas to create onsite storage shows the little space LNG takes compared a case in point. If we do not produce gas can be an efficient way of ensuring gas with uncompressed natural gas. The volume on site, we can get the gas to site in three availability and evening out spikes in supply. requirement for a CNG system at 60 bar is different ways: by truck, ship or pipeline, or Then comes the question: high pressure or already significantly smaller. using a combination of the three. low temperature, or in abbreviations: CNG In order to show the difference between Natural gas takes the role as backup fuel If you intend to connect your power or LNG? the solutions, let’s look at a case study. plant to a gas pipeline, you must answer two One power plant, a 100 MW peaking simple questions: Finding the optimal solution plant that runs five hours per day, is located 1. Can you always get gas from the When designing a CNG system, the on an island with limited infrastructure AUTHOR: Hanna Berg, Application manager, LNG, Wärtsilä Energy Solutions pipeline at an attractive price? pressure is the main point to consider. High and no LNG available. It uses a pipeline mail: [email protected] 2. Can you get the required volume you pressures give a small storage volume but with a limited gas volume. The pipeline need? incur high costs in compressors and storage gas cannot be used during peak hours of Many pipelines are struggling to cope tanks. While safety measures from different the day. However, the volume during off- with high demand. This often leads to price pressures vary, legislations adds some peaking is sufficient for a larger offtake. This spikes or shortages of gas during certain limitations too. This has to be taken into means two of the five hours it runs, the gas The market for energy production, using periods, which could further lead to costly account and optimised to see what is the supply from the pipeline is not enough. A gas, is ever growing. More customers outages or expensive power production. optimal point in the equation. small backup storage for short-term storage want to go for a pure gas engine for varied When evaluating the backup options for It is good to note that the needed amount is needed. The only acceptable solution is to reasons – environmental, legislative or a power plant the main focus should be on of backup fuel decides the feasibility of use pipeline gas during off-peak hours and even political. With this change, though, location. It is crucial to ask where the power CNG. turn it into CNG or LNG for storage. comes the need for a reliable and plant is located in relation to a gas or LNG If a large amount of fuel is needed and The most expensive equipment on CNG affordable backup solution using gas fuels. source and how it can be accessed. smaller footprint is attractive, LNG might plants is the storage tanks and the most This article will focus on the different ways If the plant is located inland, there is be a better solution. Installing liquefaction expensive part of a small-scale LNG plant is in which natural gas can be used to ensure no point considering bringing the gas in equipment and LNG storage on site can give the liquefaction. The volume of gas needed production of power in power plants. by ship. If the plant is connected by good a reliable backup with a lot of flexibility. If to be stored for the backup operation cannot 8 in detail in detail 9 [ ENERGY / IN DETAIL ] WÄRTSILÄ TECHNICAL JOURNAL 01.2018
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Break even Price split on the components of the systems 200 / IN DETAIL ENERGY [ 150 Filling storage Storage Turn into usable gas 100
Power plant size (MW) plant size Power 50
0 0 2.5 5 7.5 10 LNG CNG LNG supplied by truck Storage time (h)
Fig. 2 - Break-even point for investments between the CNG and LNG solutions, where the Fig. 3 - A rough price split between the different solutions for a 100 MW power plant at the break-even point as well as a comparison to the solution is favourable for CNG on the right and LNG on the left. cost of a system supplied by LNG trucks. (Note that this is a simplified study without considering the limitations of the systems in question.)
be changed, so the possibility to affect the simpler system of the CNG plant, storage this solution is commonly higher than those size of the LNG system is limited. The size accounts for the major cost. The cost for the of both the CNG and the LNG case, as the of the CNG plant can be affected by using regasification system for the LNG system LNG has to be contracted and transported WHY do you FOR HOW LONG do you WHEN are you going HOW can you WHAT are your higher pressure. and the pressure reduction unit in the CNG to the site. Questions need backup? need the backup? to use the backup fuel? acquire the fuel? restrictions? A comparison was made to find a break- case are relatively close in cost. The same comparison could be done to even between the investments of the two The example location explained above did trucking CNG to the site, or using ships solutions. The off-take from the pipeline not have the possibility to get LNG delivered for LNG or CNG transport. The CNG Unstable gas grid 2 hours Every day Compress to No coastal access CNG at site into the storage solution and the filling of to site. A comparison with the same system trucking and shipping is, in certain areas, Price fluctuations 2 days Every week Limited space the system is continuous. The system gets with the opportunity of getting LNG a widespread and tested technology, and in in grid Liquefy to LNG available on site Possible 2 weeks Every month at site filled in a week. The total number of hours supplied by truck is included in Figure 3. other areas it is virtually non-existent. The answers Emission LNG/CNG of backup power is presented in Figure 2. The advantage to the liquefaction on site optimal solution is based on the availability and backup Bring CNG or availability low The graph shows that, for example, when is that the production of LNG is much of these products. requirements in LNG to site by building a 100 MW power plant it is more cheaper, and the storage costs are much The case study presented only gives a legislation truck or ship cost efficient to build a compressor station lower when compared to the CNG case. In snapshot of the situation of one case in and a CNG storage facility as long as no this case the main components in the system a specific region. The case will be very more than five hours of backup is needed. are a truck loading station to receive LNG, different if we do the same exercise for Table 1 - Where to start when figuring out the backup system for your gas-pipeline-connected Wärtsilä power plant. If, however, the assumption is that the gas an LNG tank for storage and a regasification another area, another off-taker or a different pipeline will have outages of more than that system for restoring the liquid to gas. filling time for the project. If the footprint it is more cost-efficient to use a liquefaction can be larger on site, the equation could be process and have LNG storage. Money matters different: if the price for storage changes, the In Figure 3, a price split between the two The CAPEX difference between producing preference moves again towards CNG. to site is the second question: where can possibilities need to be weighed against each to reach an optimal solution, and this is not different solutions can be found. The case is gas backup on-site and bringing LNG to In the end, what backup solution is it be sourced and how will it be delivered other: is compression the most cost-efficient always an easy task. The answers are not for a 100 MW power plant at the break-even site is large. The limitation with the latter needed depends entirely on the on-site to site? If the distances are long, or the way or is it liquefaction? always clear and they might even change point (five hours of backup power needed solution is that the plant is dependent on conditions. The first question to address prices for transportation are high, it might For a way to start, please see Table 1. The during the project development. The sure per week). It can be read from the figure getting fuel delivered to site. This has to be is the size of the backup. Is the storage not be a feasible solution to rely on fuel key questions that need to be answered are thing is that solutions exist (in abundance) that the major cost for this size of LNG timed and planned, and the fuel has to be supposed to be for one hour, one day or being transported to site. If it comes down given with examples of what the answers and at least one solution is possible for each plant is the liquefaction system, but with the bought from an LNG plant. The OPEX of one week? The possibility of bringing LNG to producing backup fuel on-site, the could be. Every aspect has to be reviewed power plant. 10 in detail in detail 11 [ ENERGY / IN DETAIL ] WÄRTSILÄ TECHNICAL JOURNAL 01.2018
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The Energy Storage Systems (ESS) market is coupled with uncertain markets for ESS of fast-responding resources, like ESS, to witnessing a boom. leads to challenges of revenue forecasting. alleviate grid frequency deviations. This spurt in growth can be attributed to Owners of energy storage systems will thus Unfortunately, advanced lead-acid price declines in energy storage technology have to ‘future-proof’ their deployments batteries turned out to be an unfavourable as well as an increased need for storage to maximise their return on investments option for the case and the ERCOT ESS due to global deployment of renewables (ROIs). witnessed extreme degradation, which generation. Most importantly, energy required replacement years before the storage has become a conventional, grid- Limited track record expected end of the system’s lifetime. reliable resource. The energy storage database by the U.S. The Aliso Canyon crisis in California Department of Energy (DOE) lists only 14 Revenue uncertainty shows why. In 2015, a major leak in the grid-scale ESS projects, globally, that have Additionally, many of the vital electricity Aliso Canyon natural-gas storage facility in an operating history of at least 10 full years. market services which ESS offers are Southern California led to a high likelihood The average operational lifetime of grid- garnered via short-term contracts. of power outages for the grid. scale battery energy storage systems stands Other important services are procured In the following year, leading energy at four years and nine months. on a complete merchant basis via day-ahead storage vendors deployed three lithium- This is perhaps because a large number bidding. This is in contrast to solar and wind ion (Li-ion) battery-based systems with of the systems have been operated as pilot asset investments, which typically generate a total capacity of 70 MW / 280 MWh to projects to test a host of applications rather stable revenue for investors via long-term Next-generation energy storage systems compensate for the power capacity shortage than running as full-scale mission-critical power purchase agreements. ESS projects owing to the Aliso Canyon leak. resources similar to the present-day systems. often generate revenue via ancillary services Upon the successful completion of the In addition, vendors roll out new energy as well as capacity markets, which often do AUTHOR: David Miller, VP of Business Development, Greensmith Energy projects, the commissioner for California storage products every 12–18 months, which not come with long-term contracts. mail: [email protected] Public Utilities, Michael Picker, said, “I was means that past performance may not serve The market value and procurement stunned at the ability of batteries and the as an indication of future results. mechanism for these market services will battery industry’s ability to meet our needs. Among ESS projects that have been change in unknown ways over the life of the This was something I didn’t expect to see operational for multiple years, the track ESS asset. until 2020. Here it is in 2017, and it’s already record is mixed. To bolster the progress of Faced with a limited track record of the What is driving the growth of energy in the ground.” grid-scale storage, the DOE invested in a ESS installation base along with revenue storage? How can operators derive Estimates suggest that the ESS market is nascent project in the ERCOT market to uncertainty, the only option for an ESS owner maximum returns on their investments, expected to touch USD 7 billion by the year showcase the capability of advanced lead- to mitigate risk is to future-proof existing ESS and what are the challenges they should 2025 against USD 1.5 billion in the year 2016, acid battery technology to offer renewable investments to plan for future changes. be prepared for? We answer these registering almost a five-fold growth. firming and frequency regulation. The questions and more in our analysis. One major barrier to growth comes DOE’s objective was to procure technical What does future-proofing entail? from the risk associated with financing. and economic data from the project to gear A crucial step towards future-proofing ESS While ESS solutions are tailored to operate up for future deployments. involves deploying technology as well as for 10 years or longer, investors demand Upon its installation, the operators project engineering that primarily focuses the solutions to deliver over their lifetime found that the most profitable application on scalability. to accomplish considerable returns. The for ESS was Fast-Responding Regulation ESS projects can be future-proofed by: absence of meaningful data related to the Service (FRRS), a pilot program in ERCOT 1) installing a flexible controls architecture, long-term performance of grid-scale ESS crafted to take advantage of the capability 2) planning the right way for battery 12 in detail in detail 13 [ ENERGY / IN DETAIL ] WÄRTSILÄ TECHNICAL JOURNAL 01.2018
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Fig. 1 - The PC-based approach communicates directly with PCS controller and BMS to abstract all technology characteristics and enable technology-neutral architecture. Table 1 - Case studies demonstrating the capability of a PC-based architecture.
InverterInverter 1 1 Rack Rack Rack Rack Rack Rack OriginalOriginal Installation Installation
capacity augmentation, and 3) tracking updates to be delivered quicker and at new and old batteries separate, and with InverterInverter 2 2 BatteryBattery rack -rackbased-based Rack Rack Rack Rack Rack Rack ongoing operation with a flexible warranty. reduced costs. (Table 1) the management of new and old battery Original installation augmentationaugmentationBattery rack-based augmentation Inverter-based augmentation InverterInverter-based-based Let’s start with architecture. There are The Greensmith Energy Management banks as separate systems. This management Hypothetical system of 4 inverter Under rack-based augmentation,InverterInverter 3 3a Under inverter-based augmentation, old Rack Rack Rack Rack Rack Rack augmentationaugmentation two control architectures for ESS Energy System’s control platform, for example, is requires a flexible energy management banks, each with 3 battery racks at new battery rack is added at the end of racks from Inverter 1 are redistributed to Management Systems (EMSs): PLC-based crafted with a modular and technology- system that can co-optimize distinct assets, date of installation. battery banks. banks behind Inverters 2, 3 & 4. All new InverterInverter 4 4 and PC-based. neutral architecture. This means the same which is feasible with a PC-based EMS. Rack Rack Rack Rack RackracksRack are in one bank feeding Inverter 1. A programmable logic controller (PLC) is controls platform can be used with any (Figure 2) Inverter 1 InverterInverter 1 1 as a hardened industrial computer, designed inverter technology and battery with Finally, the battery warranty must be Rack Rack Rack Original InstallationOld Old Old Old Old Old New New InverterInverter 1 1 New New New New New New New New originally for assembly lines. PLCs are ‘hard’ minimum configuration. maintained despite any changes in operation Rack Rack Rack Rack Rack Rack Rack Rack Rack Rack Rack Rack Rack Rack Rack Rack systems that are programmed to cater to A flexible control platform also allows profile. Li-ion battery warranties are Inverter 2 Battery rack-based Rack Rack Rack InverterInverter 2 2 Old Old Old Old Old Old New New InverterInverter 2 2 Old Old Old Old Old Old Old Old specific tasks. They are programmed to flexibility to be embedded in ESS design complex. Warranty terms often include: augmentation Rack Rack Rack Rack Rack Rack Rack Rack Rack Rack Rack Rack Rack Rack Rack Rack Inverter-based accept limited inputs and outputs to achieve through a battery augmentation plan. energy throughput, peak charge/discharge Inverter 3 Rack Rack Rack InverterInverter 3 3 Old Old augmentationOld Old Old Old New New InverterInverter 3 3 Old Old Old Old Old Old Old Old the task. Battery augmentation involves leaving rate, average charge/discharge rate, average Rack Rack Rack Rack Rack Rack Rack Rack Rack Rack Rack Rack Rack Rack Rack Rack sufficient space at site for extra battery racks, temperature, maximum temperature across Modifications are possible, but they take Inverter 4 Rack Rack Rack InverterInverter 4 4 Old Old Old Old Old Old New New InverterInverter 4 4 Old Old Old Old Old Old Old Old significant time and effort and typically and scheming cable and wiring trays for measurement points, etc. In addition, the Rack Rack Rack Rack Rack Rack Rack Rack Rack Rack Rack Rack Rack Rack Rack Rack require an engineer onsite for months the future state of the system where some battery management system (BMS) does not at a time. This makes the cost of PLC battery racks could be moved and additional record these values. Inverter 1 Old Old Old New Inverter 1 New New New New modification relatively high. racks added. Without an understanding of battery Rack Rack Rack Rack Rack Rack Rack Rack Fig. 2 - Hypothetical augmentation scenarios. The charts assume a central inverter design, which is representative of most operating energy A personal computer (PC)-based The challenge with battery augmentation degradation, battery owners cannot Inverter 2 Old Old storageOld systems. New Inverter 2 Old Old Old Old controller is built on multi-purpose is that old and new battery racks cannot be determine if it will be more advantageous Rack Rack Rack Rack Rack Rack Rack Rack industrial servers and is controlled by wired in parallel to the same inverter bus. to chase additional revenue, or rest the Inverter 3 Old Old Old New Inverter 3 Old Old Old Old software. (Figure 1) If vintages are mixed, the newer battery batteries to minimize degradation. The only Rack Rack Rack Rack Rack Rack Rack Rack PC-based architecture aids complex racks are at risk of an overcurrent fault. A way for system owners to make informed Inverter 4 Old Old Old New Inverter 4 Old Old Old Old operation and optimisation and enables correct battery augmentation plan keeps decisions is to track all revenue and Rack Rack Rack Rack Rack Rack Rack Rack 14 in detail in detail 15 [ ENERGY / IN DETAIL ] WÄRTSILÄ TECHNICAL JOURNAL 01.2018
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Fig. 3 - GEMS dashboard tracks values associated with warranty compliance; provides analytics as well as full data export capability (csv).
Fig. 5 - 20 MW / 80 MWh ESS in California with planned augmentation and flexible warranty.
battery health values using dashboards and chooses to run the system less aggressively market revenue, which augments revenue analytics. These are core functions of the due to unattractive market conditions, from a bilateral capacity contract. Storage GEMS platform. (Figure 3) the augmentation can be delayed or even owners who do not consider extra merchant skipped to reduce cost as much as possible. revenue in their operational strategy will not Case study of ESS future-proofing By tracking the battery’s flexible warranty, be able to compete in tenders for long-term ESS projects designed by Greensmith for GEMS enables the system owner to make contracted revenue. the California market provide an example of tradeoff decisions for various market Greensmith has focused on crafting a future-proofing. ESS projects in California conditions (Figure 4). This future-proofed software technology and an engineering provide the state with a capacity service offering was deployed as part of a 20 MW / philosophy with scalability and flexibility in known as Resource Adequacy (RA). For 80 MWh project in 2016. (Figure 5) mind. Regardless of the changes that come energy resources that are limited such as This flexible approach provides an ESS to battery storage technology or energy ESS, RA contracts need to have four hours owner with more confidence that merchant storage market earnings, its solutions will of discharge duration at rated capacity. revenue is attainable, which boosts returns be armed with the flexibility to achieve As part of Greensmith’s future-proofed and allows for competitive bidding in RA maximum results for storage operators. ESS offering for California, GEMS tracks tenders. That’s the future. the warranted capacity of the batteries and displays trend values over time. At the same Conclusion Read the entire white paper here: time, Greensmith designs for flexibility with ESS owners must plan to future-proof https://www.wartsila.com/energy/learning-center/ a planned inverter-based augmentation in energy storage to take advantage of revenue downloads/white-papers/future-proofing-energy- storage. the middle of the system’s expected lifetime. streams that are not contracted. These If the owner chooses to run the system revenue streams are uncertain, so a flexible more aggressively for more revenue, this system design is necessary to be confident Fig. 4 - GEMS Analytics Dashboard showing forecasted battery capacity warranty based on battery usage scenario. augmentation can occur sooner with more that the revenue streams are attainable. batteries augmented. Likewise, if the owner In California, the risk includes merchant 16 in detail in detail 17 [ ENERGY / IN DETAIL ] WÄRTSILÄ TECHNICAL JOURNAL 01.2018
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Photo: 123RF
The power industry is undergoing a global falling technology costs and lower prices. involved modifying an existing 250 MW Bright prospects for Wärtsilä’s transformation. Wärtsilä is leading this The very same year, Wärtsilä launched its engine power plant with 16 Wärtsilä change with its growing focus on solar solar power strategy by introducing utility- 50DF engines delivered in 2014, and solar energy strategy photo-voltaic (PV) power solutions. scale solar photo-voltaic (PV) solutions. complementing it with a solar power plant The offering comprises utility scale solar PV of 52 MW peak capacity. plants with a capacity of 10 MW and more, This was only the beginning. In March In a review of the renewables market in as well as hybrid power plants featuring 2017, Wärtsilä announced that it had secured AUTHOR: Denise Wall 2016, the International Energy Agency, solar PV systems coupled with internal a turnkey delivery of 15 MW solar PV plant INPUTS FROM: Pekka Tolonen, Director, Solar, Wärtsilä Energy Solutions Bloomberg and many others declared combustion engines or energy storage. in Burkina Faso. This also is a hybrid facility Tarik Sfendla, Project Manager, Wärtsilä Energy Solutions that solar will lead the charge of power featuring a solar power plant constructed mail: [email protected], [email protected] generation capacity expansion in the next Solar project in Burkina Faso harnesses alongside an existing 57 MW engine power decades, far surpassing wind, hydro and advantages of hybrid logic plant powered by fuel oil. Both operate in any form of thermal power generation. The Wärtsilä moved quickly to implement the a synchronised fashion to create the largest bullish forecasts were attributed to buoyed strategy, announcing its first solar power hybrid (engine-solar) of its kind in the competitiveness in the sector driven by project in Jordan that year. The venture world. 18 in detail in detail 19 [ ENERGY / IN DETAIL ] WÄRTSILÄ TECHNICAL JOURNAL 01.2018
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The inauguration of the world’s largest Solar Hybrid power plant was attended by representatives from Iamgold and Wärtsilä, as well as the President of Burkina Faso, The new solar hybrid plant configuration maximises the utilisation of renewable energy at the Essakane mine. Mr. Roch Marc Christian Kaboré.
The project was undertaken for Essakane Wärtsilä’s hybrid plant offers many Moreover, the ability to synchronise and This development is expected to its expertise and footprint in the solar PV Solar SAS, a company with majority advantages, particularly for off-grid facilities optimise the use of engines and solar power strengthen in the next decades, thanks market. ownership by global independent power such as the Essakane mine. Cloudy skies can could see a reduction in fuel consumption to solar becoming a cheaper way of The deals Wärtsilä has secured so far are producer EREN Renewable Energy (EREN, obscure the sun and reduce the output of at the mine by roughly six million litres per producing energy than any coal or gas-fired just the tip of the iceberg in what it sees
90%) and by development partner African a solar unit by up to 80% within a minute. annum as well as an annual decrease in CO2 technologies. as a rich, renewable energy market. It is Energy Management Platform (AEMP, 10%). When skies go dark, engines can immediately emissions of some 18,500 tons. Many emerging economies are now increasingly providing solutions for utilities, As the operator of the plant, Essakane kick in and compensate for the loss of energy- prioritising access to clean and reliable IPPs and industrial customers in Africa, the Solar sells the energy generated to producing sunlight by automatically boosting Utility-scale solar PV plants in pipeline power as the bedrock for sustainable social Middle-East, Latin America and South East IAMGOLD’s Essakane mine. The off-grid by dozens of megawatts per minute if needed. Solar PV represented one third of all the and economic growth. At the same time, Asia. Rapid growth in the solar sector spells gold mine lies 350 kilometres northeast of Internal combustion engines are still the only power generation capacity increase globally developed markets are also prospecting for a bright future for the power industry. the Burkina Faso capital, Ouagadougou, and technology capable of providing such a high in 2017, with close to 100 GW added in 2017 alternative energy solutions and operational produces approximately 400,000 ounces of level of flexibility and responsiveness to power out of total of around 300 GW. This was more flexibility. These dual trends have opened up gold annually. generation. than any other power generation technology. new opportunities for Wärtsilä to develop 20 in detail in detail 21 [ ENERGY / IN DETAIL ] WÄRTSILÄ TECHNICAL JOURNAL 01.2018
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The Wärtsilä 31SG’s defining feature is This is extremely important in today’s vital. Accurate, cylinder-specific control its ability to reach efficiencies surpassing power generation landscape, where the algorithms are essential for a gas engine 50% – a milestone within the industry. aggressive growth of renewable sources operating with firing pressures this high. By comparison, simple-cycle gas turbines has triggered a disruptive change. For this reason, as part of the development typically have an efficiency of around 40%. Conventional baseload is disappearing as of this engine, Wärtsilä went to great lengths Wärtsilä’s existing generating sets had power generators take on the new role of to create a next-generation automation already far surpassed that mark, but this intermittently backing up the grid when system, which is integrated into the engine new engine widens the gap even further, the output from renewables dips. This itself. The system was built entirely in-house / IN DETAIL ENERGY [ representing a significant cost savings shift represents a huge challenge for plant based on new hardware and software. potential for power producers, as well as owners. Combined cycle power plants The engine automation system is lower emissions. cannot cope with the daily starts, stops, and distinctive for its wide implementation of continuously changing load patterns that are digital controls, which regulate valve timing, Efficiency under pressure becoming the new norm. gas admission, ignition, coolant temperature Designing a new engine entirely from the An internal combustion engine, on the and various aspects of the turbocharging. It’s bottom up gave Wärtsilä’s engineers the unique other hand, is just the right tool for the job this high degree of automation that allows opportunity to examine all of the various thanks to its dramatically more flexible the Wärtsilä 31SG to account for differences factors that contribute to engine efficiency, operating profile. Needless to say, engineers in fuel as well as run at various loads making improvements in each to achieve the wanted to push the Wärtsilä 31SG’s flexibility without compromising efficiency. most possible gain. Combustion quality, heat to the cutting edge. The new automation hardware is and flow loss prevention, and internal friction A major contributor to the engine’s modular and integrated. All sensors are were among the issues exhaustively explored increased flexibility is its completely connected directly to the control ports, and addressed to their fullest. redesigned valve actuation method. The new without going through connectors or The most critical advance in the Wärtsilä design replaced the mechanical, rocker arm- junction boxes – a change that reduces the 31SG, however, was an engine structure driven valve mechanism of previous models likelihood of faults. The equipment was designed expressly to accommodate two- with a hydraulic system, similar to those used also subject to rigorous vibration and heat stage turbocharging. While the considerable in the car industry. This feature allows very testing to ensure that it would stand up boost in efficiency associated with two- smooth and precise control of valve timing to to the difficult environment of an engine stage turbocharging was well known – the ensure that the fuel-air ratio in the cylinder is room, further boosting reliability. industry had already been experimenting optimised at all times. It’s in this way that the Wärtsilä 31SG, the world’s most with it for quite some time – no existing engine can take maximum advantage of the The long view engines were capable of taking full advantage boost provided by two-stage turbocharging, The advantage of a more efficient engine like of the effect. They simply could not stand specifically so on partial loads. the Wärtsilä 31SG is obvious at times when efficient 4-stroke engine up to the loading and strain that results Optimised engine parameters and fuel prices are relatively high. Yet interest from the step change in firing pressure. adjustable inlet valve timing combined with in the engine has been strong in all of our To overcome this, engineers gave Wärtsilä electronic ignition timing result in fewer markets, despite the fact that gas prices in AUTHORS: Jani Mäkinen, Senior Development Manager, Genset Portfolio 31SG’s entire engine structure a very robust unburned hydrocarbons and thus vastly certain regions are fairly advantageous at the Erik Jungner, General Manager, Genset Portfolio at Wärtsilä Energy Solutions design with an unprecedented break mean improved efficiency and lower emissions moment. Today’s investors recognise that an mail: [email protected], [email protected] effective pressure (BMEP) of 30 bars. irrespective of the load. An added bonus of engine of this type is a long-term investment Naturally, having a design that the hydraulic valve actuation concept is that and that fuel prices can fluctuate radically incorporates efficiency-boosting concepts there’s no need for valve clearance adjustment. from year to year, from decade to decade. is one thing while bringing a new engine to The level of flexibility found in the Wärtsilä These investors take a holistic approach, life is another. Development of the Wärtsilä 31SG is hard to overstate. The engine can be seeking both the lower lifecycle costs In the price-sensitive field of electrical The internal combustion engine has been than improving an existing design, they 31SG was a long and complex process that continuously operated at 10% load and can associated with prolonged maintenance power generation, efficiency and flexibility through a lot since its advent roughly 200 started from a completely blank slate to involved extensive computer simulation, reach full load within as little as two minutes intervals, and a buffer against potential are the hottest commodities. Wärtsilä’s years ago. It’s fascinating to consider that, develop a new engine family that would be testing on a single-cylinder experimental of the start command. shifts in the fuel markets. newest engine marks a step change despite all the advancements made through considerably more efficient than anything engine then testing on a number of multi- On a more general scale, the world is likely in both, delivering an industry-leading decades of tinkering and tweaking, this that had come before. cylinder engines. All this was carried out to Total control to see a dramatic reduction in fossil fuel- efficiency of over 50 percent. The secret 18th-century concept continues to be the The result: Wärtsilä 31, available in diesel, guarantee that the efficiency gains would be Automation is a key element of any modern burning power generation in the coming to its success is a ground-breaking new basis of so much power production today. dual-fuel and pure gas variants. Recently realized and that the final product would gas engine, underpinning efficiency, safety decades. This change will come about not design, conceived entirely from scratch, And the consensus is that there are still introduced is the spark-ignited Wärtsilä meet the highest standards of reliability. and flexibility, but there are particular only because of higher fuel prices, but also that makes it tough enough to withstand more avenues for design improvement that 31SG, the 20-cylinder version which requirements for a machine as advanced from political pressure leading to legal limits the heavy mechanical loading associated simply need to be worked out and tested. produces 12 MW of power. When the first Flexibility for today’s power needs and complex as the Wärtsilä 31SG. With 20 on emissions. The solutions that survive the with two-stage turbocharging. It was with this thinking, six years Wärtsilä 20V31SG rolled off the production A fundamental advantage of the Wärtsilä cylinders each firing six times per second test of time will be those that are most flexible ago, that engineers at Wärtsilä set out to lines last year, it became the world’s most 31SG is its flexibility – its ability to start and so many variables coming into play, and efficient. In both these categories, the do something that is quite rare among efficient simple-cycle internal combustion up quickly and maintain high efficiency the ability to easily harmonise and control Wärtsilä 31SG has a clear advantage. This is manufacturers of large engines. Rather engine ever built. throughout the entire load range. every aspect of the operation is absolutely an engine built for the future. 22 in detail in detail 23 [ MARINE / IN DETAIL ] WÄRTSILÄ TECHNICAL JOURNAL 01.2018
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VER fuel version skid showing the 2 stage compressor along with condenser and separator. Fig. 1 - System overview – VER re-absorption version. Wärtsilä Voyage Emission Reduction An oil tanker emits on average 0.085% of its tank, while tankers powered by Liquefied VOC emissions from cargo tanks contained cargo every week. This may not Natural Gas (LNG) will be able to convert contain both methane and non-methane system turns emissions into fuel sound like much, but if you take a 320,000 the VOC into fuel for use during the voyage. hydrocarbons. Considering the example of deadweight tonnage (DWT) Very Large Both systems represent a unique, game- the VLCC that operates 20 weeks of laden Crude Carrier (VLCC) as an example, this changing opportunity to increase revenues voyages and loses 5400 tonnes of cargo in AUTHOR: Hans Jakob Buvarp, Product Manager, VOC Wärtsilä Marine Solutions apparently small amount actually adds up to while, at the same time, significantly the form of VOC each year, this translates mail: [email protected] 270 tonnes of lost cargo every week. Take it reducing the vessel’s environmental impact. to the equivalent of up to 20,000 tonnes
a step further and look at an entire year and of CO2 per year. With the Wärtsilä VER, you will end up with a massive 5400 tonnes VER re-absorption version – 80% of that VOC is re-absorbed, thereby of lost cargo, assuming that the VLCC for conventional VLCCs reducing local pollution by 80%. operates laden voyages for 20 weeks every The version of the VER that has been A VLCC that re-absorbs 80% of the 5400 Wärtsilä has developed a groundbreaking year. designed for conventional VLCCs is based tonnes of cargo that would otherwise have new system that allows oil tankers to However, with Wärtsilä’s cutting-edge on a straightforward technology: a simple been lost will be able to deliver an extra return potentially harmful volatile organic Voyage Emission Reduction (VER) system, plug-in unit captures the VOC that would 4320 tonnes of cargo each year. This is compound (VOC) emissions to the cargo it will be possible to make losses like this otherwise be lost and recirculates it back equivalent to 27,700 barrels of oil, which, in tank, reducing cargo losses by up to 80%. a thing of the past. The groundbreaking into the cargo tanks. In doing so, it prevents turn, represents a huge amount of money The new Voyage Emission Reduction (VER) system allows up to 96% of the VOC that the loss of up to 270 tonnes of cargo a week, – USD 1.9 million to be precise, based on system is available in two versions – one is typically lost as boil-off to be converted while, at the same time, protecting the present-day oil prices. Considering that a for conventional oil tankers and another back into fuel. On a conventional VLCC, the environment from these potentially harmful re-absorption version Wärtsilä VER costs for LNG-fuelled tankers. VOC emissions will go back into the cargo emissions. (Figure 1) around USD 1.2 million to install, the 24 in detail in detail 25 [ MARINE / IN DETAIL ] WÄRTSILÄ TECHNICAL JOURNAL 01.2018
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Fig. 2 - Re-absorption process flow diagram.
return on investment is excellent, equating The container is connected to the cargo Its oil consumption amounts to less than to a payback time of a little more than six tank vent line to allow the inlet of vapour 0.5 l/day of operation. It has an air-cooled months. and to the cargo stripping line to enable electrical motor with a power requirement The Wärtsilä VER re-absorption version the VOC to be returned to the cargo tanks. of 35/46 kW. It also has an air-cooled heat is likely to be of particular interest to the The stripping pipe inlet on one or more of exchanger that serves three purposes: global oil majors. Most fleet operators own the tanks needs to be fitted with a simple firstly it cools the compressed VOC to an the ships but not the cargo, but when an installation for gas absorption, in order for air temperature of + 5°C, secondly it cools oil company owns the entire value chain, the gas to be distributed for re-absorption the glycol and, last but not least, it creates including a fleet of, say, 40 vessels, the into the cargo. (Figure 2) ventilation for the container. The VER opportunity to recover more than 4000 Operation is automatic and no manual system also comes with auxiliary equipment tonnes of oil a year would translate into a intervention is required. The plant operates such as a glycol pump, inlet filter and total saving of more than 160,000 tonnes within a fixed cargo tank pressure range and re-absorption units for three or four cargo of oil per annum, or USD 77 million worth stops automatically at low pressure, while an tanks. (Figure 3) of oil. automatic vent is activated at high pressure. As far as service and maintenance goes, Easy operation How does the VER re-absorption routine maintenance will typically be carried What makes the Wärtsilä VER re-absorption version work? out after the compressor and glycol pump version even more unique is that it is so The Wärtsilä VER has been designed have accumulated 5000 running hours. user-friendly. The automatic system includes for easy installation, operation and Standard maintenance includes changing the a control panel that monitors the plant and maintenance. It comes in two versions; inlet filter and applying lube oil to the system. sets off an alarm in the event low levels of either with a capacity of up to 400m3/h lubrication oil, of low levels of glycol, high (tankers up to 160 kTDW), or up to Innovative features temperature in the gas outlet, low suction 800m3/h (tankers up to 320 kTDW). Both The Wärtsilä VER re-absorption version pressure, or high bearing temperature on the versions are delivered in a container that contains innovative features that combine to motor and compressor. Lube oil can be filled includes all the equipment needed to run make it a simple plug-and-play solution. up from outside of the container and levels the system. The only utility the ship needs to Firstly, the rotary vane compressor on the can easily be monitored using the gauges on Fig. 3 - Typical fully equipped container – VER re-absorption version. provide is electrical power. VER is glycol-cooled with oil lubrication. the outside of the container. 26 in detail in detail 27 [ MARINE / IN DETAIL ] WÄRTSILÄ TECHNICAL JOURNAL 01.2018
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Arrangement / IN DETAIL MARINE [
Deck Module
LNG Vaporizer Mixing Unit
VOC LNG Tank LVOC Tank LVOC Vaporizer condensation
Fig. 4 - SIMPLE PROCESS – fuel gas mixing with SVOC and LNG.
Low pressure Main Engines
1 © Wärtsilä 22 March 2018 VER™ Fig. 6 - VER equipment can be located in a deck module with the LNG heater / vaporizer skid.
VER fuel version – for LNG-fuelled VLCCs up to 20% for LNG-fuelled fuel tankers by and used in the engines. The fuel mixing The fuel version of the Wärtsilä VER is mixing VOC with LNG fuel, enabling the system continuously controls the mixing designed especially for VLCCs operating vessel to operate on the mixture. ratio between VOC and LNG in order to on LNG. While the existing LNG-fuelled maintain the correct methane number VLCC fleet is extremely small – with only 20 How does the fuel version VER work? (MN). (Figure 5) vessels on order at the present time – there One of the features that make this In addition to the VER plant itself, a small is every indication that this market will only system unique is its ability to reduce fuel deckhouse containing all the fuel-related continue to grow going forward. With the consumption during both laden and ballast equipment, such as the VOC plant, VOC IMO’s 2020 sulphur cap regulation coming voyages. The recovery and mixing system vaporiser, LNG heater and vaporiser skid, into effect in less than two years’ time, the on the Wärtsilä VER fuel version consists and mixing valve unit, needs to be installed. market is in urgent need of a fuel alternative of an inlet filter, a VOC compressor, a VOC In addition, an LVOC tank and LNG tank that will enable it to comply with new condenser, a separator, an LVOC tank and will need to be installed on deck. (Figure 6) requirements, and LNG is quickly emerging a mixing unit. In short, the system works The Wärtsilä VER fuel version will be as one of the most viable solutions. As by compressing the VOC to a pressure of 16 available in two sizes: a smaller version for a result, demand for LNG across all barg for two-stroke or eight barg for four- up to 160,000 DWT and a larger version for shipping segments is expected to increase stroke engines. (Figure 4) 160,000 to 320,000 DWT. significantly in the coming years. After compression, a sea water cooler The Wärtsilä VER fuel version is based reduces the temperature of the compressed on a patent-pending recovery and mixing VOC and consequently some of the VOC technology. The technology has already been condenses and can be stored in a tank for thoroughly tested at Wärtsilä’s test facilities use during the ballast voyage. During the for both four-stroke and two-stroke engines Laden Voyage the non-condensed VOC and is currently being installed on North Sea (SVOC) is mixed with LNG fuel and used shuttle tankers at Samsung Heavy Industries in the engines. During the ballast voyage, Fig. 5 - LADEN VOYAGE – fuel gas mixing with SVOC and LNG and BALLAST VOYAGE – fuel gas mixing with LVOC and LNG. (SHI). Tests have demonstrated that the liquid VOC, collected during the laden VER fuel version is able to deliver savings of voyage, is vaporised, mixed with LNG 28 in detail in detail 29 [ MARINE / IN DETAIL ] WÄRTSILÄ TECHNICAL JOURNAL 01.2018
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900 rpm 1000 rpm 1200 rpm
4L20 740 kW 800 kW N/A
6L20 1110 kW 1200 kW 1320 kW / IN DETAIL MARINE
[ 8L20 1480 kW 1600 kW 1760 kW
9L20 1665 kW 1800 kW 1980 kW
New KBB turbocharger version ST5 EP (8L20).
Because the upgraded Wärtsilä 20 engine launched at the Marintec conference and panel showing the engine’s operational data is a refinement of an existing engine, there is exhibition in Shanghai, China on 5–8 – temperature, pressure, hours, etc. – on also a high level of spare parts compatibility. December, 2017. an LED touch screen. The important thing In addition, maintenance procedures remain Following is a breakdown of some of the here is that the available information is the unchanged, a welcome development for Wärtsilä 20 new developments: same for the user, who will not notice any everyone. First of all, the new engine is difference, but the design is improved for denominated with the ‘E’ suffix indicating Wärtsilä and the interface is simpler. What’s new? (as in Wärtsilä 20E and Wärtsilä Auxpac As far as the actual engine block, cylinder New automation system including a touch screen display. New wastegate with hydraulic actuator. Like its predecessor, the new Wärtsilä 20E) its (alphabetic, and other) evolution heads and camshaft are concerned, a few 20, which will take two years to develop over previous models, with both models new flanges and connecting holes have been (all versions), can be used as an auxiliary achieving a 10% higher output at 1200 rpms machined in to allow for cooling pipes. engine to produce electricity on board, as a but still based on the classic Wärtsilä A new injection system was also installed generation set for electrical propulsion, or 20 engine design. The intention is for across the whole Wärtsilä 20 range. Wärtsilä 20 – Small changes, big results for direct mechanical propulsion. In theory, the Wärtsilä Auxpac 20E to replace the The key to tweaking additional rpms all Wärtsilä 20 engines can be upgraded to former Wärtsilä Auxpac 20D3/D4 as an and capacity on the upgraded Wärtsilä the new performance parameters. auxiliary generator set which is, for Wärtsilä 20 stems from the turbocharger and The original Wärtsilä 20 is a four-stroke internally, an enormous reduction in compressor aspects where a new cooling AUTHOR: Johan Kålax, Product Manager, Small bore, Wärtsilä Marine Solutions diesel engine that can be run on light fuel oil complexity and spare parts handling, a cost pipe arrangement is needed to reduce the mail: [email protected] (LFO) and heavy fuel oil (HFO). The engine which is naturally and eventually passed on internal temperatures of the turbocharger. can switch from LFO to HFO and vice versa to the customer. Another major improvement comes in without power interruption at any engine The higher cylinder output will the form of a new AWG (Air Waste Gate) operational load. The Wärtsilä 20 has proven be available in 6-, 8- and 9-cylinder valve, which previously was a pneumatic robustness and reliability, with over 6000 configurations, and due to the new system and not very accurate. The new Lisk We revisit a classic, making it better In the world of big diesel engines and from 900 to 1200 for 60Hz generating sets, engines delivered since it was introduced to automation system (UNIC 2) including valve is a hydraulic set-up (borrowed from and more efficient than ever before. The generators, everyone wants more bang for for instance. It is an example of doing more the market in the early 1990s. a new main cabinet, now equipped with the high-speed engine industry) which has upgraded Wärtsilä 20 engine comes with the buck. with less. The Wärtsilä 20 is especially suitable for a touch screen display, will be somewhat improved functionality. It will also yield a a host of new features, making it a great But there are only two ways to get higher This technology is passed over from the the 1.3-2.0 MW merchant auxiliary fleet longer (30.3 cm–37.2 cm) than previous longer lifespan. choice for marine vessels. output from an engine. The first is to increase already established Wärtsilä 20DF (dual- segment. It is also the perfect fit as the main models and will weigh between 9.3 and 11.6 Other improvements include a new cable the firing pressure at a fixed rotational fuel) engine, which has been running at this propulsor in smaller ships including fishing, tonnes. rail for the electrical equipment, new piston speed, which usually is not possible without speed from the introduction in 2011, without tugs and offshore and support vessels, and Most of the new engine components rings, a new injection pump and valve. extensive redesign of many parts. The second any issues. covers the lower power range within the are based on the earlier Wärtsilä 20 diesel Commonalities between the old and new method, and the most economical, is to With an increased cylinder output of Wärtsilä diesel engine family. The engine is engine with a few tweaks. engine exist because the basic design of the increase the rotations-per-minute (rpm) of 220 kW at 1200 rpms, the upgraded engine fully compliant with the IMO Tier II exhaust whole engine remains untouched. the engine at a fixed firing pressure. is a high-value-added proposition for emissions regulations set out in Annex VI of The red thread It is also possible to retrofit a diesel into In December 2017, Wärtsilä announced the yards building merchant ships, and the MARPOL 73/78 convention. Also IMO Both new engines – Wärtsilä 20 and a dual-fuel unit. In these cases, required an upgraded version of its popular Wärtsilä ultimately ship owners looking for lighter Tier III compliance is possible together with Wärtsilä Auxpac 20 – have a Wärtsilä UNIC changes include pistons, piston rings, 20 diesel engine which does just this – and more compact engine configurations a Wärtsilä NOR NOx reducer and associated engine control/automation system, which cylinder heads (with injectors and valves), increases maximum rpms from 1000 to to achieve higher payloads with almost the equipment. is designed for the harshest environments camshaft and electrical equipment including 1200 for mechanical propulsion engines and same low fuel consumption. The new Wärtsilä 20 engine was officially and includes an engine-mounted control brackets. 30 in detail in detail 31 [ MARINE / IN DETAIL ] WÄRTSILÄ TECHNICAL JOURNAL 01.2018
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Fig. 1 - These images show the difference between how the thruster stream interacts with the hull Wärtsilä’s new retractable thruster is an depending on whether a conventional thruster or a tilted thruster is installed. improvement across all parameters
Five years ago, Wärtsilä embarked on a kW, the same as with the LMT-FS1510, costs, safer and simpler installation, less AUTHOR: Vincent Klous, Product Development Manager, Propulsion, Wärtsilä Marine Solutions complete renewal of its entire thruster making it an ideal choice for vessels such as space taken up on the vessel, and a reduced mail: [email protected] portfolio, with dynamic positioning shuttle tankers, and offshore support and risk of oil leaking to the environment. applications built around a more construction vessels. hydrodynamically efficient eight-degree The new design has been developed over a Complete redesign tilted gearbox. The process, which started period of more than 18 months by a team at Since the redesign began at the start of with the launch of the WST drilling series, Wärtsilä Marine’s Technology and Services 2016, Wärtsilä’s team has kept in close The WST-24R thruster, with its eight- moved to the next stage last December with Center in Drunen, and is an improvement contact with ship owners and yards, to degree tilted propeller shaft configuration, the official launch of the WST-24R, the on the LMT-FS1510 across all parameters. make sure that the product meets their delivers 23% more effective thrust than its world’s first retractable thruster with a tilted Effective thrust has been increased by 23% requirements for a retractable thruster. This predecessor, uses less fuel and takes up gearbox and electric steering and retraction. compared to a conventional unit with a has pushed the team to significantly alter the less space on board. Like its predecessor, the LMT-FS1510, 90-degree gearbox and a tilted nozzle, design focus, making ease of installation, the WST-24R has been developed for lowering fuel consumption and operational serviceability and maintenance as much a vessels that require the safety of dynamic cost while also improving the vessel’s priority as performance. positioning while operating on offshore dynamic positioning performance. With a conventional thruster (with a sites, but also need to be able to retract The lean design means fewer components, 90-degree gearbox) such as the LMT-FS1510, them en route. It has a power rating of 2400 which translates into lower maintenance the downward deflection of the jet is not 32 in detail in detail 33 [ MARINE / IN DETAIL ] WÄRTSILÄ TECHNICAL JOURNAL 01.2018
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The eight-degree tilt also combats this by deflecting the jet to reduce ‘forbidden zones’ where thrusters cannot operate without blowing into other thrusters. Simply adding a tilted gearbox to the existing LMT-FS1510 design would have significantly increased the amount of space / IN DETAIL MARINE [ taken up on board by the thruster unit, because the additional angle implies a longer retraction length. To prevent this, Wärtsilä redesigned the entire thruster, including the inboard parts, to make the system more compact. The hydraulic retraction and steering mechanisms used on the LMT-FS1510 have Fig. 3 - WST-24R new spindle retraction system. been replaced by a more lightweight and compact electric system. A significant amount of space on board has been freed up by the decision to use a single drive cabinet to control the three electric used to retract the thruster permanently The thruster has been designed to be sent motors used for steering and retraction. loaded under tension regardless the to yards in a single delivery, with each unit When a thruster is being retracted, there is direction of the forces acting on the pre-assembled and pre-aligned at Wärtsilä’s no need to steer it, and when a vessel is being spindles. This prevents the spindles from factory. The thrusters are then installed and steered, there is no need to retract, making a buckling; subsequently a thinner spindle can levelled at the yard, with alignment checked second drive redundant. be used for the same load. (Figure 3) using a 3D laser scanner. Switching to electric systems also The thruster can also be delivered as eliminates the risk of hydraulic fluids Single seal inboard demountable unit, effectively leaking, causing marine pollution and an The WST-24R uses a single, specially shaped avoiding the costs and risks associated with unsafe slippery workspace for crew, and seal developed for Wärtsilä by a leading dry docking. makes the set-up easier to maintain. manufacturer to protect both the steering The unit is also equipped with an The WST-24R can be delivered with and retraction mechanisms. This means that additional inflatable seal which is activated a 2600mm or 2800mm propeller rather the thruster has one less oil-to-sea interface when the thruster is retracted, preventing than the 2500mm propeller used on the than the LMT-FS1510, with its two seals, any water entering inboard. The inflatable LMT-FS1510, reducing the power density. reducing the risk of oil leaking into the seal also allows the combined retraction / Combined with improvements to the environment. steering seals to be serviced inboard without hydrodynamic shape of the propeller The WST-24R’s seal is essentially a rotary the need to dry dock. gearbox and nozzle, the WST-24R generates seal that has also been made suitable for The composite steering support bearing 10% more unit thrust with the same power linear motions by incorporating elements of for the tilted gearbox is also designed to be even without the improvements in hull- hydraulic cylinder seals. serviceable by divers in water. thruster interaction. (Figure 2) It is a significant improvement on both the stuffing box seals used for the Conclusions New patent application for LMT-FS1510 retraction mechanism and lip The additional challenge implied by retraction mechanism seals for steering. installing an eight-degree tilted gearbox has Fig. 2 - The Wärtsilä WST-24R thruster offers more effective thrust than comparable conventional thrusters. The push to develop a more compact The old stuffing box seals in particular pushed the development team working on retraction system led the Drunen team to were difficult to make completely tight, the WST-24R to carry out an even more develop, and then file a patent for, a new always leading to water leaking inboard. complete redesign than that carried out on mechanism for retracting the thruster using The new seal is designed sturdier and the rest of the renewed steerable thruster tension-loaded spindles. tighter, reducing water ingress inboard to an portfolio. enough to stop the stream from the thruster with Warstila’s drilling steerable thruster Typically, in a shuttle tanker or pipe- The new mechanism has allowed the absolute minimum during operation. One month after launch, Wärtsilä is hitting the bottom of the ship, causing high family, the complete pod, shaft line, propeller laying vessel, two to three retractable diameter of the spindles to be reduced from already close to entering an exclusivity interaction losses between the thruster and and nozzle is tilted by eight degrees. This is thrusters will operate alongside two to three 330mm to 80mm to lift the same load. Because Easy installation and maintenance agreement with a major ship owner, the adjacent hull. A nozzle tilted five degrees the tilt angle that research indicates is enough main steerable thrusters and between one the spindles are self-locking, the new design The thruster’s streamlined, plug-and-play showing that the unit’s increased operational counteracts this to some extent, but the to deflect the jet downward sufficiently to and two tunnel thrusters. also eliminates the need to apply external design means that it can be installed on performance, reduced cost of installation effective thrust is still significantly reduced. clear the hull without significantly reducing In this configuration there is a further locking hooks when the thruster is retracted. vessels as a single package, taking less time and easier maintenance is likely to make it a On the other hand, in the WST-24R as horizontal thrust. (Figure 1) risk of thruster–to-thruster interaction. The new mechanism keeps the spindles and using less labour. popular choice for years to come. 34 in detail in detail 35 [ MARINE / IN DETAIL ] WÄRTSILÄ TECHNICAL JOURNAL 01.2018
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Wärtsilä’s new family of environment- hybrid propulsion, and the designs are able to friendly tugs is here! It is based on cover a 40 to 90t bollard pull range with the the Wärtsilä HY concept, and draws appropriate Wärtsilä equipment modules. inspiration from the company’s proven LNG technology. We tell you how these A ‘battery’ of better solutions innovative tug designs translate into Ngoh considers development of battery improved efficiency. power as one of the fastest-evolving technologies for energy storage that has a huge leg up on safety size, and cost. “Wärtsilä’s constant technological development on engines, E&A and thrusters “Wärtsilä’s journey to provide environment- also provides further improvement to friendly tug designs started in 2014 when system efficiency,” says Ngoh, adding that the liquefied natural gas (LNG) Eco Tug was the new designs also bring flexibility and introduced,” remembers Joost Van Eijnatten, efficiency by using less engine power, which Manager Application Engineering, decreases emissions, fuel bills and the need Propulsion, Wärtsilä Marine Solutions. for massive engine maintenance. Tugs with LNG as fuel or with hybrid The company has found a perfect partner technology place higher demands on in its own thrusters. The Wärtsilä Steerable the design and on the integration of the Thrusters (WSTs) have a large-diameter different systems on board and this, he says, propeller to provide high performance is typically where Wärtsilä can excel and add propulsion with excellent hydrodynamics. more value. “They are reliable and easy to install, Interestingly, Wärtsilä has successfully operate and maintain,” points out Van delivered many proven dual-fuel and hybrid Eijnatten, adding that the efficiency and low solutions for different vessel types, and the operational costs enabled by WST thrusters new eco-friendly tugs are an extension of enhances environmental friendliness and this endeavour. overall economics of the new tugs. “With Wärtsilä’s reputation in Asia as a And the new tugs have done well to find formidable tug designer, the family of new their place in the new scheme of things. eco-friendly HY Tugs drive in as a perfect For starters, they have significantly vehicle to further strengthen our position reduced fuel consumption and associated
in the market,” says Ay Hwa Ngoh, Offshore CO2 emissions as well as NOx, SOx and & Specials Sales Manager in Wärtsilä’s Ship particle emissions. For the tug designs Design. having LNG as fuel, the emissions are even These newly launched Wärtsilä HY Tug lower. The Wärtsilä HY Tug features a zero- designs come in three different hull sizes, smoke design, meaning that no smoke Eco-friendly tugs make a splash namely a 28m harbour tug with a 50t bollard is visible when the engines are started or pull, a 29.5m harbour tug and a 35m escort running. When running fully electric on tug – both with a 75t bollard pull. The the batteries, there are no emissions at all. propulsion configuration is such that each This zero-emission mode is especially useful AUTHOR: Ronak Kotecha design comes with the option to select either when starting or idling at port or during diesel mechanical hybrid or diesel electric transit and standby modes. 36 in detail in detail 37 [ MARINE / IN DETAIL ] WÄRTSILÄ TECHNICAL JOURNAL 01.2018
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Wärtsilä HY – a fully integrated Key benefits of Wärtsilä HY
hybrid power module • Guaranteed module performance • Instant load taking capability The standard mechanically driven configuration • No visible smoke under all normal conditions includes: • Green mode (zero emissions) • Main engine with on/off clutch • Optimised plant dimensioning • PTO/PTI on the gearbox (or in-line shaft • Built-in redundancy What’s more, the thrusters are equipped optimised to provide the best performance. “The Wärtsilä HY Tug designs have been generator/motor) • Reduced maintenance (less cylinder-hours, with seal monitoring, to monitor possible Ngoh points out the practicability of the designed in close co-operation with the • Energy storage system reduced stress to the components) lubrication oil leakage to the seawater. new tugs, which is due to its distinct design ABS, BV and Lloyds Register classification • DC link and power drives • Increased efficiency (lower fuel consumption, “While environmentally acceptable that is optimised for low hull resistance, societies, and received Approval-in- • Energy Management System fewer emissions) lubricant (EAL) can be used for lubrication high escort performance, good sea-keeping, Principle (AiP) certification,” says Ngoh. The standard electrically driven configuration • Ship type optimised design and specific of the thruster gears, bearings and seals, in safety and comfort for the crew. Some of the As the total solutions provider, Wärtsilä includes: application tuning the unlikely event of a spill, the oil does not new features include the special wheelhouse has the unique vantage point with its • Generating set • Wärtsilä is the single supplier harm the environment even in the case of a design with improved 360-degree visibility capability to produce these new tug designs • Energy storage system leakage,” assures Van Eijnatten. for single-man operation, and introduction with its unparalleled expertise and in-house • DC link and power drives of side shoulders and semi enclosure for resources. • Energy Management System Operational performance the bow winch for safety of the crew during It seems the decks are now clear for the Operationally, the new tugs are not only towing operation. The designs also come dawn of a greener tomorrow with eco- modern and environment-friendly, but also with a unique and modern exterior outlook. friendly tugs leading the way. 38 in detail in detail 39 [ MARINE / IN DETAIL ] WÄRTSILÄ TECHNICAL JOURNAL 01.2018
] / IN DETAIL MARINE [ The development of the new Wärtsilä 31 Pilot Delivery Unit. “This model is what we engine provided the perfect opportunity now refer to as Design for Manufacturability to exploit the benefits of modularisation (DFM), which in turn is part of our New and put the concept of Design for Product Introduction process (NPI). In Manufacturability into practice. practice, DFM means that specific assembly and component manufacturing experts join the product development project at an early phase. They start to design how the product The design and development of the Wärtsilä will be produced at the same time as the 31 engine have presented a great opportunity product designers are getting to work.” to implement a design process model based on a high level of modularisation. The Faster process, better quality wide range of benefits in doing so include Work is done at a component level by maintained operational excellence during instructing the product designer to make manufacturing, reductions in lead time and component features in such a way that guaranteed reliability. the parts are easy to produce, explains “Wärtsilä 31 is a product of Mäenpää, eliminating the need to make modularisation, which means it is based on technical compromises in production. If a different architecture from previous engine such compromises are necessary, they can platforms,” says Patrik Wägar, Product be identified during the design phase. DFM Director, Medium Bore Engines, Marine also means the engine assembly structure Solutions. “This enables a lot of benefits, is also developed in parallel and makes although we need to be prepared to exploit possible more extensive product preparation and maintain them. This is key to enable in the sub-assembly phase, thus speeding a more flexible and less complex portfolio up the overall production process and going forward.” increasing quality. Modular product architecture means “From the point of view of DFM, when breaking down the product into property- manufacturing structure and process are driven building blocks – modules – with designed in parallel with the product, we defined interfaces. “It’s a representation can then also design and develop related of a product family which consists of production tooling,” says Mäenpää. “The modules and its variants,” explains Mika result is faster product ramp-up and fewer Yli-Salomäki, Senior Manager Platform changes after production has started. All Architecture, Technology, Engines, Marine this is coordinated within the NPI process Solutions. for each product development. DFM “In addition to facilitating shorter lead allows manufacturing experts to play a times from configuration to order, modular part in prototype production as well as in product architecture makes it easier to fit developing the manufacturing process.” customer needs and provide high-quality, When describing product design Modularisation hand in hand accurately validated solutions, a faster modularity in the context of DFM, Mäenpää introduction of new features, and easier likens the process to providing Lego bricks upgrades and conversions.” for manufacturing experts at an early stage. with manufacturability “During the Wärtsilä 31 engine “First drafts for the assembly structure development project we secured the were made using these modules, even involvement of manufacturing experts in before the details were known of what parts AUTHOR: Tim Bird the design process,” says Juho Mäenpää, each module would contain. While design General Manager, Delivery Centre Vaasa modules were developed and product design 40 in detail in detail 41 [ MARINE / IN DETAIL ] WÄRTSILÄ TECHNICAL JOURNAL 01.2018
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have pre-engineered and pre-validated Accurate simulation upgrade existing products partly using components with standardised interfaces. It Accuracy of simulations in design is concepts from the Wärtsilä 31 development, moves the installation and commission risk another asset, says Wägar. “As recently as but the main gain is for the future. For other earlier into the supply chain and increases five years ago, we were still surprised at products in our portfolio apart from engines, the chances for successful commissioning the discrepancy between simulations and the journey has started, and we see great / IN DETAIL MARINE [ trials.” reality. These days we are surprised at how benefits for ship builders and customers The supply chain will focus more and accurate our simulations have become. for having modularised products with more on the entire process from design The capacity for accurate simulations is a fixed interfaces, offering shorter lead times, to user experience, and not just on the major value for a company.” Validation, to reduced risk and a higher degree of pre- connection between companies. Wärtsilä’s check that specifications meet customer engineering and testing before installation.” focus on operational excellence will also be needs, is also enhanced by DFM, and Wägar “This development has involved great sharpened, eliminating process waste and insists that the Wärtsilä 31 is the most co-operation across the organisational strengthening connectivity between the extensively validated engine ever released by borders,” says Mäenpää. “Many different company and its suppliers. Wärtsilä. He sees the next step as creating segments of the company have been “From sourcing to sales, everyone needs a “digital twin” – a virtual engine that can working together to develop and introduce to understand the reasons for adopting be used to analyse and evaluate design and a great engine – in fact, the best of its modularisation and how to utilise the performance, without the need to construct kind. This way of working will increase benefits with this knowledge,” says Wägar. a physical engine for these purposes. the level of information for all parties. Of “Suppliers need to take more responsibility “For other engine products on the drawing course we need to continue this work and for delivering module variants instead of board, our DFM experiences with the adhere closely to the new rules we have loose components, while quality processes Wärtsilä 31 help us develop our approach been creating, so that we can look back on need to be more closely aligned as well. and processes to make sure we capture many more projects with pride at this clear It calls for stronger incorporation of sub- the synergies,” Wägar continues. “We can product modularity.” supplier processes into our own. “We needed a new platform for further development,” he says. “The Wärtsilä 32 engine has been with us for some time, and the previous latest output stage was introduced in 2012. The new Wärtsilä 31 broke the Guinness World Record in efficiency for any 4-stroke engine, in competition with much larger engines.” All in all, he says, it’s the engine for the The Wärtsilä 31 is the most extensively validated engine ever released by Wärtsilä. digital era, in the context of self-tuning engines, self-trouble-shooting and self- adaptation. Nine engines had been sold to marine installations as of September 2017, with references ranging from icebreakers to was progressing, we also had the chance to far with the assembly of an engine before fact that the same approach will be taken fishing vessels. The first delivery has been influence what those details might be, up to deciding the fuel type or specific customer in developing future new products. Room made, and the first engine is scheduled to a point.” needs. You can add those modules that for improvement still exists, he believes, become operational in spring 2018. In general, products have traditionally are relevant for the project towards the in improving external modularisation, in Speed of innovation and technology been designed on the basis of performance end of the assembly. This approach has which engine interfaces with other products development will only accelerate in the and cost, with less focus on the many benefits, but it does require close can be managed. future, Wägar believes. Past limitations to manufacturing process, says Wägar. cooperation with assembly line operators “Fewer component variants means development have been largely eliminated, Modularisation combined with DFM makes and suppliers.” volume synergies, while for the assembly while Wärtsilä’s success has always been in Wärtsilä an industry leader. process it means reduced risk and shortened proportion to its focus on and investment “With the Wärtsilä 31 we have developed More customer benefits lead time,” says Wägar. “The core team in R&D, a factor that has delivered highly a product architecture that allows for This combined approach also passes around the new Wärtsilä 31 product has competitive products. Efficiency is always smart modularisation whereby we can on direct customer benefits in terms of been accountable for enabling the concept, a top priority for the company, and energy achieve more combinations using fewer shorter lead time, faster maintenance and we have also had external consultants efficiency has always been a key driver. The variants or modules,” says Wägar. “With and fewer components. Wägar expresses included in the process. From any turnkey DFM approach will only serve to underline modularisation, you can also proceed quite satisfaction both at this potential and the builder’s point of view, it is a benefit to these factors. 42 in detail in detail 43 [ SERVICES / IN DETAIL ] WÄRTSILÄ TECHNICAL JOURNAL 01.2018
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Blade efficiency during one revolution of a 4-bladed propeller.
With cutting fuel costs such a high priority structure consisting of multiple fins attached fundamental traits: it had to be robust for ship operators, marine engineers are to the ship’s hull that were designed to shift enough to withstand both long-term fatigue Wärtsilä EnergoFlow increases fuel efficiency by up to 10%. constantly looking for ways to squeeze the part of the wake downward for a better angle and the roughest weather, optimise the flow most propulsive power out of every bit of of attack. Though the basic theory behind into the propeller to maximise propeller energy that goes into an engine. One way the PSS was sound, early examples on the efficiency, and minimise viscous resistances. to do that is to dampen down the rotational market couldn’t effectively control the water’s Also, applying a PSS can lead to additional losses that result from the way water flows flow direction, and weak structural design hull and rudder resistance, which can result Wärtsilä EnergoFlow boosts into a ship’s propeller blades. left them prone to cracking or breaking off at in considerably less net gain. This factor had Due to the shape of a typical ship’s hull, the first sign of rough weather. to be addressed as well. the water leaving its aft flows steadily at Designs soon improved, however, and the The fail-safe design of the Wärtsilä propulsion efficiency a slight upward angle as it moves toward PSS eventually gained enough interest to be EnergoFlow was achieved by both taking the propeller. At the downward stroke of chosen for study by GRIP (Green Retrofitting into account fatigue – the low-level the propeller, the 3 o’clock position when through Improved Propulsion), an stresses that occur over the lifetime of a AUTHOR: Steve Roman viewed from aft, this upward inflow angle EU-funded research project carried out from ship – and carefully studying the effects is ideal since the blades are moving against 2011 to 2015 to investigate various energy- of peak load, or the maximum stresses it and can thus better accelerate the moving saving options in the marine market. Wärtsilä that a ship might encounter once every flow. On the opposite side of the propeller, and the nine other European companies 25 years. For the latter, Wärtsilä used however, both the water and the blade are participating in GRIP put the PSS concept a modelling technique that treated the Last year, Wärtsilä launched its latest moving upward, minimising the propeller’s under their collective microscope and, Wärtsilä EnergoFlow’s fins as if they were energy-saving device for ship engines, a ability to push against the water and thereby after gaining a deeper understanding of the a propeller blade attached to the ship, then next-generation pre-swirl stator dubbed weakening overall propulsion power. hydrodynamic principles involved, came up looked at the stress effects of various wave the Wärtsilä EnergoFlow. The innovative This situation can best be compared to with a better working model. In sea trials on heights combined with the ship’s vertical apparatus, available for both retrofits and an airplane with head- or tailwind during a bulk carrier, GRIP’s PSS achieved a power motion, sailing speed, pitch, roll and other new-builds, is already attracting attention takeoff. In case of a tailwind, the lift of the savings of 7%. factors. Once the requirements were fully with the substantial fuel savings it can wings is reduced, thereby elongating takeoff understood, designers were able to adjust yield – up to 10% in certain cases. The key distance. Modelling the fins the fins’ thickness, width, length and camber to its propulsion-boosting power is how To counteract this effect, engineers over To build on the successes of GRIP and accordingly to create a product with a it controls the complex hydrodynamics a decade ago began experimenting with develop the Wärtsilä EnergoFlow, Wärtsilä’s 25-year lifetime. They also added a ring, upstream of the propeller. the idea of a pre-swirl stator (PSS), a static engineers had to design a model with three or arched segment that connects the fins 44 in detail in detail 45 [ SERVICES / IN DETAIL ] WÄRTSILÄ TECHNICAL JOURNAL 01.2018
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Power reduction vs. Power Loading coefficient. Model tests carried out for validating the strength of the EnergoFlow.
at their tips, which serves to distribute the one individually using CFD modelling to determined by the specifics of each case, force that might act on any one fin under create a strategy for installing the Wärtsilä but there are some generalities based on an extreme condition such as slamming, EnergoFlow. The stator itself is custom- ship type. Bulk carriers, for instance, can when the ship’s aft repeatedly rises out of the designed for each case, with possible see fuel savings in the 10% range. Container water. Model tests carried out to measure variations in the shape of the fins and, in ships, which are already relatively efficient forces in both normal and storm conditions some circumstances, even the number of in propulsion terms, would still see a found that the ring decreases the maximum fins when the typical three-fin approach isn’t respectable 4% improvement, but this could occurring stress on each fin by about 40%. the best solution. also climb to 10% if a new propeller design For fine-tuning the pre-swirl flow and Hull integration must be carried out by for slow steaming applications is made. The lowering viscous resistance, Wärtsilä relied a welded connection to the cast bossing or savings figure for tankers falls roughly in the on the latest CFD modelling to create stern tube to ensure structural soundness. middle of the two. its design. The result can be seen in the Sometimes this can result in limited options Regardless of the ship type, the Wärtsilä pronounced curvature of the fins in the for optimizing the positioning of the stator EnergoFlow typically pays for itself within Wärtsilä EnergoFlow. relative to the propeller, but Wärtsilä one to two years of operation. Given the But it’s important to note that the Wärtsilä engineers can usually find a solution even high potential for savings and short payback EnergoFlow concept is about more than within these constraints. times – not to mention the environmental the design of the stator itself, since it’s The most crucial factor in the Wärtsilä benefits of burning less fuel – this could be a the hydrodynamic interplay between the EnergoFlow setup, however, is propeller true game-changer for ship owners. stator, the hull and the propeller that will pairing. The system works best when a ship’s ultimately determine how accurately the propeller is specifically designed to work flow can be directed and how much viscous with the PSS – a factor than can boost the resistance will be added. Therefore, the power savings by up to 2%. Wärtsilä has the positioning of the stator and the design of capability to modify an existing propeller the propeller are critical parts of the package by removing pieces at the trailing edge to and are key elements in the power savings give it a new pitch angle, but in cases where equation. the resulting fuel savings would be large enough, it would make sense for a ship Custom-designing solutions owner to invest in a new propeller. As every ship design and operating Just how much power – and therefore Stress distribution [Pa] of fins and stern structure for typical bulk carrier with reference load on the fins. profile is unique, Wärtsilä assesses each fuel – savings can be achieved is again 46 in detail in detail 47 [ FUTURE / IN DETAIL ] WÄRTSILÄ TECHNICAL JOURNAL 01.2018
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KNL Networks and Portcall.com were the winners of the first SparkUp Challenge.
promising ideas and partner them with KNL Networks’ team called the SparkUp industry experts. It is part of Wärtsilä’s five- process amazing yet challenging. level Tiered Venturing Model. “I really can’t hide my smile,” said Tomi / IN DETAIL FUTURE [ “I believe this approach will help Linden from KNL Networks after the win. bring in new and fresh ways of thinking “Wärtsilä’s mind-set has changed. They are to help us with our work,” notes Alid looking for a big impact – and fast.” Dettke, Vice President, Open Innovation. Wärtsilä provides the winning teams with Dettke compares the model to forming space and mentoring for up to six months, a relationship. First one gets to know the as well as a capital grant of EUR 50,000. other, and step by step things might proceed Now, Portcall.com and KNL Networks to more and more serious levels. face a collaboration period in the Digital “At Wärtsilä, we are looking for a special Acceleration Centre, DAC. The projects, someone.” including an incubation phase and a go-to- The first phase of the challenge focused market transformation, will culminate in a on Wärtsilä’s Smart Marine Vision. The Demo Day later in 2018. company looked for innovative start-ups For Wärtsilä, the most important aspect to develop ideas for the smart shipping of the challenge is the ability to connect value chain in collaboration with Wärtsilä. the innovative solution to business. “We The winning team was promised an also look forward to moving on with the incubation period in Wärtsilä’s Digital finalists and their projects,” says Steffen Acceleration Centres (DACs) in Helsinki or Knodt, Director, Digital Ventures. “This is a Singapore. These hubs are where projects are learning process for all of us.” developed at unprecedented speeds, often The future is, by default, a learning in collaboration with start-ups and other process. SparkUp Challenge is one way to partners. prepare for it. “You cannot shy away from the future,” The winning teams Dettke points out. “We must roll up our The challenge, which attracted almost sleeves, embrace it boldly and grow with it.” 150 entries, reached its peak at the end of The second SparkUp Challenge, focusing February, when a full day of co-creation on Smart Energy, will be launched in the with Wärtsilä mentors and pitching led to fall of 2018. The concept is set to become a the announcement of the winner of the key part of the strategy of building effective very first SparkUp Challenge. A total of 11 and fruitful long-term partnerships with pitches, mostly focusing on connectivity and start-ups. green solutions, were of such high quality “This is an amazing opportunity to that the jury had difficulty deciding on just co-create with us, and really accelerate the one out of the lot. development of innovative digital services,” In the end, the task proved impossible. adds Dettke. The jury decided to name not one but Marco Ryan, Chief Digital Officer for Wärtsilä’s SparkUp Challenge aims for the two winners: KNL Networks and Portcall. Wärtsilä, holds a similar view. SparkUp SparkUp Challenge invites perfect match between the company’s com. The first offers reliable data networks Challenge along with the DAC concept business and innovative start-ups. for ships, and the latter has developed a accelerate Wärtsilä’s digital transformation collaboration platform that logs incoming journey towards an ‘as-a-service’ smart start-ups to innovate and The Wärtsilä SparkUp Challenge is an and outgoing ships in ports. technology company. opportunity to shine a light on a newly “I did not expect to win, with all these “We at Wärtsilä are renowned for spotting co-create together with Wärtsilä discovered innovation or business idea that amazing participants,” said Portcall.com’s trends and innovation,” he says. “The best could disrupt a whole industry – if only it Bryan Bender after the announcement, results will happen, he says, when engineers, was found and developed further. brimming with excitement. business people, data scientists and UX The goal of the challenge, launched “This has been a great opportunity to experts sit together and work collaboratively AUTHORS: Sofia Kilpikivi, Lotta Heikkeri, Anne Salomäki at the Slush start-up event in November work with Wärtsilä. I enjoyed the approach towards a common goal that meets the 2017, is to identify start-ups with the most and the synergy we got.” needs of our customers.” 48 in detail in detail 49