THE GLOBAL MAGAZINE FOR MARINE CUSTOMERS ISSUE 24 2015 MERCY MISSION HOW ROLLS-ROYCE SUPPORTS MEDICAL SHIPS IN AFRICA

THE PERFECT

PERMANENT MAGNETMATCH TECHNOLOGY FOR BETTER THRUSTER PERFORMANCE

INSIDE MARINE NEWS AND DEVELOPMENTS / TECHNOLOGY / UPDATES / CUSTOMER SUPPORT rolls-royce.com E&P_Rig_1_1_032015 from 1843to7760kWel Trusted todeliver excellence and optimisedlife-cycle costs. ­performance and flexibility, reduced fuelc ­solutions meetthechallenging combination ofhigh ­fairleads and generating sets. Our­ ­positioning systems, anchor and ­ mountable/demountable ­ ­accommodation rigs. Systems comprise underwater ­applications like ­ ­system solutionsfor abroad range ofoffshore Rolls-Royce iswidelyrecognised for itsproducts and positioning propulsion and Solutions for power, Generating sets drillships, drillingrigsand mountable/demountable azimuth thrusters Underwater thrusters, dynamic mooring winches, products and offshore applications ­onsumption Deck machinery customised to WELCOME

Solutions for power, propulsion and positioning

MIKAEL MÄKINEN, PRESIDENT – MARINE, ROLLS-ROYCE EFFICIENCY DRIVES FUTURE SUCCESS Rolls-Royce continues to focus on innovation based on its depth of experience, drawing on half a century of heritage to unveil a completely new permanent magnet azimuth thruster

Efficient operation is fundamental propulsion packages, rather than through many stages to today’s to the success of any business, and bespoke systems selected around wide range, suited to numerous THE GLOBAL MAGAZINE FOR MARINE CUSTOMERS ISSUE 24 2015 MERCY MISSION for those in shipping, efficiency is an owner’s preference. Standard HOW ROLLS-ROYCE ship types. Our latest designs share SUPPORTS MEDICAL SHIPS IN AFRICA the key when planning the future. packages won’t suit all, but in terms that innovative pedigree and build Getting the most out of your assets, of driving down cost, simplifying on five decades of research and

and doing so throughout the life fleets and monitoring performance THE operating experience. So, to coincide PERFECT of a vessel, remains a key objective MATCH with Nor-Shipping in June (also in through life, there are clear benefits PERMANENT MAGNET TECHNOLOGY FOR BETTER THRUSTER PERFORMANCE for our customers and we’re seeing in off-the-shelf solutions. While INSIDE MARINE NEWS AND DEVELOPMENTS / TECHNOLOGY / UPDATES / CUSTOMER SUPPORT its 50th year), we will unveil a new growing interest in the need to the hull lines will always reflect the COVER: Rolls-Royce permanent magnet azimuth thruster. will feature permanent guarantee performance levels. creativity of a naval architect, what magnet technology at This new design combines advanced Nor-Shipping in June. At Rolls-Royce we focus on the lies beneath could indeed become hydrodynamics with our latest efficiency of our products, taking a more of a standard and scalable permanent magnet technology, long-term view to ensure they live offering, giving proven reliability and and we think this will be the future up to our promises not only when measurable efficiencies. direction of marine propulsion. they leave our factories, but after A key part of any vessel is of course We have continued to develop many years in service. the propulsion system, and the In-depth and we would like to hear We’re seeing a growing trend in efficiency of the propulsors can make your views, about both our print and customers demanding performance a real difference to the bottom line. digital editions for iPad and Android. through life, not only from individual One example is with the azimuth Your reviews are important to us, products but also from integrated thruster. Today it is a workhorse so if you can find time to complete systems, designed to match vessel of the shipping world, providing our survey it would be much operating requirements. power and manoeuvrability. Turn appreciated. In this issue, we take a look at a the clock back 50 years and it was For those of you going to new range of propulsion systems an innovative but small piece of Nor-Shipping, I look forward to we’ve designed for an emerging technology. seeing you there. An event like this market of ‘adventure’ cruise ships. In the 50 years since Rolls-Royce gives us all an opportunity to take We think the future of shipbuilding delivered the first azimuth thrusters, in what’s new and perhaps catch a will in time shift towards standard we have led their development clearer view of the future.

03 CONTENTS

ISSUE 24 2015

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NEWS AND FEATURES 03 WELCOME cruise vessel operators select the right Rolls-Royce is able to draw on its propulsion system to suit their needs heritage to drive future success, says TECHNOLOGY Mikael Mäkinen, President – Marine 10 TESTING TIME The research ship Gunnerus is the CUSTOMER FOCUS 06 NEWS ROUND UP ideal vessel to analyse the application The latest developments from the of permanent magnet motor 20 HELPING HANDS world of Rolls-Royce technology on azimuth thruster Last year, Rolls-Royce officially development become a supporter of Mercy Ships, an international charity with the mission to increase global access to healthcare INTERVIEW 14 INTELLIGENCE through a fleet of hospital ships AND THE BRIDGE 08 CULTURE OF INNOVATION In-depth looks at what the future holds Senior Vice President, Technology for intelligent bridge design following Management and Innovation, Sauli the introduction of the Unified Bridge UPDATES Eloranta, tells In-depth about the dedication to developing innovative 24 50 YEARS OF technology for now and the future 18 TAKE YOUR PICK The Rolls-Royce Blue Ocean team has AZIMUTH THRUSTERS developed a range of options to help In May, Rolls-Royce can look back on 50

04 GET IN TOUCH

Our offices and sector contacts, as well as key websites and portals, are listed on the inside back cover

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NEWS AND FEATURES ABOUT

years of azimuth thruster innovation. Fincantieri were looking for efficiency, Opinions expressed may not necessarily represent the views of low noise and manoeuvrability for Rolls-Royce or the editorial team. The publishers cannot accept In both design and performance, the liability for errors or omissions. All photographs © Rolls-Royce three new cruise ships they turned plc unless otherwise stated. In which case copyright owned by technology has come a long way photographer/organisation. to Rolls-Royce technology EDITOR: Andrew Rice DESIGNED AND PRODUCED BY: Connect Publications Ltd 28 GOLD DIGGER CONTRIBUTORS: RW – Richard White; AR – Andrew Rice; Rolls-Royce propulsion equipment is set PW - Patrik Wheater If your details have changed or if you wish to receive a regular to power an innovative seabed mining CUSTOMER SUPPORT complimentary copy of In-depth please email us at: ship, opening up a new market for the [email protected] Printed in the UK. shipping industry 34 KEEP ON EARNING In response to the need to reduce 30 THE BALANCING ACT downtime, Rolls-Royce now offers Rolls-Royce designers deal with vastly a full turnkey support package for differing needs when it comes to UUC azimuth thrusters to minimise

propeller design. Decades of experience operational disruption © Rolls-Royce plc 2015 studying hydrodynamic and cavitation The information in this document is the property of Rolls-Royce plc efficiency are critical in meeting each and may not be copied, communicated to a third party, or used for 38 TO THE MAX any purpose other than that for which it is supplied, without the customer’s requirement A dedicated Rolls-Royce facility to test express written consent of Rolls-Royce plc. While the information is given in good faith, based upon the the gas turbines on the Royal Navy’s latest information available to Rolls-Royce plc, no warranty or Type 45 fleet will support the destroyers’ representation is given concerning such information, which 32 A STAR IS BORN must not be taken as establishing any contractual or other demanding schedules commitment binding upon Rolls-Royce plc or any of its subsidiary When cruise operator Viking Oceans and or associated companies.

05 NEWS Maersk first for new anchor recovery frame providing a much safer working deck environment for ships’ crews. It makes for a Award for more efficient operation.” Unlike existing anchorhandling frames, Unified Bridge which have a 90 degree operating angle, The Unified Bridge from the new ARF can be operated at 126° to the Rolls-Royce has won the deck by two hydraulic cylinders and a free- Norwegian Design Council 2015 rotating roller. award for design excellence. Capable of operation in temperatures The awarding jury said: “In a Maersk Supply Service has exercised an ranging from -20 to -45 degrees Celsius, conservative business with many option to add new anchor recovery frames the recovery system has a nominal towline class regulations, it is a challenging (ARFs) to the supply contract awarded tension capacity of 200 tonnes with a lateral task to develop innovative solutions in December for deck machinery for six force of 50 tonnes. for user interfaces. This solution high-end anchorhandlers under construction In addition to the six ARFs, the scope of appears significantly better than at Norway’s Kleven Verft AS. supply also includes Rolls-Royce rudders competing solutions, and the The contract marks the first reference and steering gear. quality of the interaction design is for the next generation ARF, designed in Rolls-Royce will deliver the ARFs from high. The user interface is based on cooperation with Maersk to optimise vessel February 2016. modern navigational principles. The safety and efficiency. work surfaces Runar Hjelle, Area Sales Manager, said: are layered, “The new system is designed to reduce the which enable Digital loads generated when anchors are lifted from navigation on To see more of sea to deck, and lowered from the deck into one surface, the Rolls-Royce Unified Bridge the sea. and with the in action, download “When not in use, this innovative recovery touchscreen the digital edition of In-depth from frame is stowed in a deck recess protected reduces iTunes or Googleplay by a mechanically operated hatch cover, cognitive load for operators.”

L6 AG auxiliary engine to generate 1,560kWe in the year. The new engine will be fully of clean power, dramatically reducing integrated into the electricity plant on emissions during port stays in Barcelona and the vessel, enabling operation with any Palma de Mallorca. of the on-board auxiliaries. Testing and Baleària is Spain’s leading shipping implementation work is expected to take company, with a fleet of 20 vessels operating place towards the end of next year. between the Iberian peninsula, the Balearic When Abel Matutes is in port, the Islands, the Strait of Gibraltar and the gas engine will be connected to the Baleària Bahamas, and is committed to developing distribution infrastructure ashore or the LNG as a marine fuel. onboard LNG tank. Baleària Group President Adolfo Utor said: moves to LNG “This is a very important milestone that will Rolls-Royce has signed a collaboration enable us to be pioneers in the use of natural agreement with Spanish energy company gas on ferries and, at the same time, be more

Gas Natural Fenosa to develop and install sustainable. Besides reducing CO2 emissions a pure-gas Bergen engine aboard the by 40 per cent, it also enables us to reduce Baleària-operated ferry Abel Matutes. fuel costs. Abel Matutes may well find herself This is the first reference for a pure-gas deployed on a route in an Emissions Control engine installation on a European-flagged Area (ECA) sometime in the future.” ferry operating outside of Norwegian waters. Baleària and Rolls-Royce aim to carry out The 29,670 tonne ropax ferry, delivered in pre-installation work in early 2015, prior to 2010, will use an LNG-fuelled Bergen C26:33 the vessel’s scheduled dry docking later

06 INSET: Rolls-Royce will supply MTU high-speed engines and a suite of Kamewa waterjet propulsion systems for the Qatar Coastguard.

MTU diesels and Kamewa waterjets to power Qatar Coastguard vessels

Rolls-Royce is to supply MTU high-speed first Qatar Coastguard craft to be propelled develop the designs for the vessels, which engines and a suite of waterjet propulsion by Rolls-Royce Kamewa waterjets, so we’re meet the customer’s stringent performance systems for 17 fast patrol vessels now under delighted to welcome them as our latest and comfort requirements. construction at Turkey’s ARES Shipyard for customer. This is not the first project we have Kerim Kalafatoglu, ARES Shipyard the Qatar Coastguard. worked on with ARES Shipyard, but it is the Chairman and Executive Director, said: This order comprises systems for three largest and most important.” “Our partnerships with suppliers such different vessel sizes that will be built from For optimum fuel economy at high- as Rolls-Royce are testament to our advanced composites: five 24m vessels speeds, the combination of Rolls-Royce commitment to deliver quality vessels at capable of speeds in excess of 37 knots, 10 MTU diesels and Kamewa waterjets are the leading edge of design and innovation. of 34m capable of achieving 30 knots and major contributors to the enhanced This contract for 17 craft for the Qatar two of 47m also capable of 30 knots. efficiency and performance of these highly Coastguard is one of the most significant MTU 12V2000M84 diesel engines and capable craft. In particular, our Kamewa A3 for fibre-reinforced plastic (FRP) patrol boats Kamewa 50A3 series waterjets will power waterjets offers high performance up to ever signed.” the 24m ARES 75 Hercules patrol boats and speeds of around 45 knots. Rolls-Royce will supply a total of 46 MTU the 34m ARES 110 Hercules design. BMT Nigel Gee was the chosen designer engines and waterjets across the three The two largest craft, the 47-metre ARES for the project and is responsible for the naval different sizes of craft. The first vessel is 150 Hercules design, will each feature architecture, including hull development, scheduled for sea trials early in 2016. three MTU Series 4000 diesels driving class level design and engineering work on twin Kamewa 71S4 waterjets and a central all three sizes of vessel. Rolls-Royce provided booster. technical support throughout the design Don Roussinos, President Naval, said: “The phase. BMT’s team of naval architects and ARES Hercules series patrol boats will be the engineers has worked closely with ARES to

April June Poland 2015 14-17 LAAD, Rio de 2-5 Norshipping, 15-18 DSEI, London, UK Janeiro, Brazil Oslo, Norway Nov 21-23 Sea Asia, 3-5 UDT, Rotterdam, Marine Events Oct 3-6 Europort, Singapore Netherlands Rolls-Royce and MTU will be attending 6-8 Pacific 2015, Rotterdam, 9-11 Seawork, Sydney, Australia Netherlands these events. For further information, May Southampton, UK 4-7 OTC, Houston, 7-9 Danfish, Aalborg, contact: Donna Wightman 23-26 Brazil Offshore, USA Denmark Dec Global Event Manager Rio de Janerio 5-8 IDEF, Istanbul, 18-23 SEG, New 1-4 Marintec, [email protected] Turkey Sept Orleans, USA Shanghai, China 19-21 IMDEX Asia, 1-4, MSPO 20-23 Kormarine, 3-5 Work Boat Show, Singapore Expo, Kielce, Busan, Korea New Orleans, USA

07 INTERVIEW A culture of

As Senior Vice President, Technology Management SAULI ELORANTA market. The 800 or so UT design INNOVATIONvessels built to date prove that ship and Innovation, Sauli Eloranta is not only dedicated “Good and innovative engineering and design is an enabler, and reduces the to ensuring the right technology is being developed therefore a well- risk for the customer. It shows the motivated engineering community is vital to importance of the right equipment for customers today. He is equally focused on the our future success. The enemy is playing fit to ensure the vessel meets the innovations they might not yet have imagined it safe.” needs of the customer. Being able to design the ship and the equipment that powers it has been an exciting evolution, in the quest for efficiency auli Eloranta leads the seem wide and sporadic, but that gains, to drive down operating costs. technology and innovation is not the individual customer view. The biggest change has been activities at Rolls-Royce They know our products even better in the industry’s developments in Marine. In-depth editor than we do because they live with simulation to revolutionise maritime SAndrew Rice found out about his them onboard, for the life of the crew training and improve safety. views on marine technology today vessel. Virtually all activities carried out and where it is heading in the future. If there is one thing I have learned onboard can now be undertaken during my career it’s that ‘business safely from simulators. This rapid AR: You came to this role from rules’. My priority is to ensure advance in computing power has the shipbuilding sector. What the engineering and technology spawned a variety of other product experiences have helped shape function provides the services and advances and provided us with the your thinking and priorities? products our customers need, and big data we are now harnessing to SE: Having worked in senior R&D and will add value to their operations. improve vessel performance. engineering positions in yards that Then there is the technology include Kvaerner, Aker Yards and STX AR: What do you consider to introduced to meet international in Finland, plus yards in the US and be the most exciting change in emission and environmental France, each has its own approach marine technology recently? regulations. The first vessels soley and identity. SE: When I joined in 2010, I was powered by LNG only began arriving They are experienced, agile and amazed at how Rolls-Royce had 15 years ago, but today they are innovative but have individual delivered ‘standard’ UT design into triple figures and growing, as strengths. vessels to the distinct and the bunkering infrastructure Finnish yards can be lean and different sectors of develops. pragmatic and French yards have the offshore an excellent focus on the detail. In the US, the yard in Philadelphia was down to earth, and I had the task of reintroducing commercial shipbuilding after a long absence, invaluable experience that has when planning new product introductions. As the engineering director, I met many customers and those insights continue to guide me. Understanding different cultural and business needs is important as we work with most of the world’s shipyards. Our objective is to propose the most suitable solution for each customer. The marine market may

08 energy or make ship operations safer. Electrical products for marine applications have taken time to come to market, but not at the expense of reliability. The trend is for offerings related to ship intelligence, so that is key to R&D spend.

AR: What do you see as the key marine technology drivers? SE: The market focus is shifting from just specifying marine equipment hardware to hardware that comes with the appropriate software to maximise its reliability and minimise maintenance. Value adding data services such as equipment health monitoring will be the new norm. And this information will be available onboard and at onshore control centres. As ships become more intelligent, crews are likely to become smaller, but better trained. As communication channels become more readily available, certain tasks will be moved onshore.

AR: How do you address the good leader can drive out ambiguity, AR: What is the most challenging challenge of creating an maintain the edge in design and part of your job? environment where innovation select features for the final design. SE: I view myself as a pragmatist. can flourish, but not at the When decisions have been made, expense of reliability and safety? AR: In your customer meetings, getting things actioned quickly is SE: Good and innovative do you find there are areas important but challenging with engineering and a well-motivated where technology is lagging multiple stakeholders. We have engineering community are vital to behind their needs? some of the best assets of any our success. The enemy is playing SE: Customers want proven, efficient, marine business, so identifying the it safe. An innovative culture needs reliable and affordable solutions, and right technologies to invest in is not nurturing in the form of constructive different sectors have different value always straightforward. challenging, encouragement, drivers. Drillship operators with high Getting the best out of empowerment and leadership, daily rates demand reliability to avoid engineering teams, ensuring they where a level of freedom exists. disruptions, whereas cargo carriers have clear accountabilities and are Many innovations happen behind need ship and propulsion efficiency. aligned is a key part of my role and the scenes by like-minded individuals To handle subsea systems from not always easy. Finally, finding the getting together. This often starts vessels and not rigs is now an option right balance of listening and action by listening to our customers’ issues, using fibre rope systems. It has taken to make the right business decision. then devising a solution. a while to gain acceptance, but the Innovation is difficult to drive out gap has now been filled with the AR: When not working, what do by monthly meetings and it is technology similar to lifts in high-rise you do to unwind? difficult to dictate the pace. I favour buildings to replace steel wire rope. SE: Home for me is in the Finnish initiatives that stimulate innovation Customers can identify gaps countryside. Our summer house, and small teams with an experienced where technology can be applied or rather a winter house in Finland, leader to act as coach and judge. A to either improve performance, save requires constant attention, so I can often be found doing improvement projects in the dark with a headlamp. Our four children have grown up “A GOOD LEADER CAN DRIVE OUT but my wife and I still get together AMBIGUITY, MAINTAINING THE EDGE with them frequently. I also enjoy swimming, no matter the time of IN DESIGN AND IN SELECTING FEATURES year. It’s surprising how invigorating TO BE PART OF THE FINAL DESIGN” it is, but I am a Finn! AR

09 TECHNOLOGY

Testing

TIMEThe research ship Gunnerus is the ideal vessel to analyse the application of permanent magnet motor technology on azimuth thruster development

zimuth thrusters are now As built, the ship has diesel electric propulsion in a being tested with permanent traditional twin screw arrangement. For the new thruster magnet (PM) motor applications, fit, Moen Marin won the contract for the conversion following the installation of two work, with Polarconsult designing the hull modfications PM azimuth thrusters on the to accept the azimuth thruster mountings and feed the research ship Gunnerus. Testing propulsion forces into the structure. will continue through 2015. The original high-speed diesel generator sets are Gunnerus is 31.25m retained, and have been fitted with extremely long, was designed flexible mountings to stop any structural- by Polarconsult and borne noise potentially affecting research delivered by the Larsnes Mek. Verksted shipyard Digital results. As part of the conversion work the in Norway in 2006. It is owned and operated Watch the propellers, shaftlines, rudders and steering permanent magnet byA the Norwegian University of Science and azimuth thruster gear have been removed, and the sterntubes on spin test in our Technology (NTNU), based in Trondheim, and digital edition of plugged, but the skeg remains in place. In-depth, available equipped to carry out research in the fields free on iTunes and These technology demonstrator PM azimuth of biology, technology, geology, archeology, Googleplay thrusters will have a rating of 500kW to match oceanography and fisheries, and so supports the test vessel’s available power, but the many of the courses offered by NTNU. When propeller diameter is generous for the loading, the ship was conceived the aim was that it should not which means a thruster with the same diameter propeller only be a platform for scientific research, but also a tool for can handle up to 1,000kW. the development of innovative marine technology. This Each thruster comprises three main assemblies – the secondary role is the one Gunnerus will now undertake, a PM motor/propeller/nozzle underwater unit, the hull key part of the thruster development work. mounting system, which includes the azimuth bearing

10 TOP AND LEFT: Two and duplicate frequency controlled electric steering gear, PM azimuth thrusters and the inboard power unit which feeds electric power conservatively rated at 500kW have been to the thruster. fitted to the research vessel Gunnerus. The PM motor is built into the nozzle and the propeller FAR LEFT: CFD has has an advanced forward skew blade design. Nozzle been used extensively shape can be selected to suit individual applications, but in the development of the new PM azimuth since Gunnerus requires pull for towing trawls and other thruster. gear, the nozzle is optimised for bollard pull and speed to match the vessel’s requirements. The installation is compact, with only the slip ring unit and the variable frequency steering motors inside the hull. In other respects the azimuth thruster uses the same technology as the PM tunnel thrusters. Under a multi-partner agreement, Rolls-Royce is the lead partner, with NTNU as shipowner and operator. The project has been awarded funding from MAROFF, the marine arm of Forskningsrådet – the Research & Technology. “Because of the research work Gunnerus Council of Norway. Other partners are Marintek, DNV, does, it is well equipped to do many jobs that will benefit Olympic Shipping and the Technical University in from the added manoeuvrability the azimuth thrusters Ålesund. Through its UTC (University Technology Centre) will confer, and it is also designed to be quiet. programme, Rolls-Royce already has a longstanding “A dynamic positioning (DP) system and High Precision relationship with Marintek and NTNU on marine Acoustic Positioning (HiPAP) reference system allows propulsion and hydrodynamics research, while Olympic Gunnerus to be accurately positioned for deploying Shipping has for several years been linked to the PM research equipment. tunnel thruster development work through its vessel “The machinery is also arranged so that the minimum Olympic Octopus. of noise is radiated into the water, which should allow “The vessel and thrusters are an ideal match,” says us to get a very clear picture of all aspects of thruster Gunnar Johnsen, Head of Electrical Systems Research performance.” RW

11 TECHNOLOGY PM TECHNOLOGY

GAINSTunnel thrusters with Rolls-Royce permanentACCEPTANCE magnet (PM) motor technology are producing excellent results for a range of operators, with orders for offshore construction vessels, pipelayers and a cruise ship

oth azimuth and tunnel thruster designs are based on the rim drive principle where the motor surrounds the propeller as a slim ring. A stator carries the electromagnetic windings fed by a frequency converter that creates a rotating magnetic field. The rotorB is integral with the propeller and carries a series of permanent magnets. As the magnetic fields interact, the propeller turns. This forms a compact and efficient unit easy to install in a tunnel. Power output is also increased by that also shape water flow to and from the propeller. around 25 per cent from the same propeller size. Installation of these PM tunnel thrusters is made easy “In a traditional tunnel thruster the propeller blades’ for the shipyard. With the steel tunnel integrated in the tips run close to the tunnel wall, but even so there hull, the thruster can be fitted at a later stage to suit are tip losses,” says Göran Grunditz, Manager of the the yard schedule. A jig is used to position the flexible Hydrodynamic Research Centre. “With the PM thruster, mounts, and then the complete thruster is slid into the the blades go into the ring and rotate together, reducing tunnel and bolted in place. The only items in the thruster cavitation. The loading of the blades is reduced because room are the terminal box and cable connections to the of the design of the housing.” variable frequency power supply. A long and intensive development process has led to the production tunnel thruster, currently built in two Low noise sizes PMTT1600 (1,000kW) and PMTT2000 (1,600kW) and A fully instrumented PM tunnel thruster is installed on the engineered for ease of installation or exchange either in anchorhandler Olympic Octopus. In noise measurement a dock or underwater. 5dB reduction is perceived by the human ear as a halving An efficiency of 97.5 per cent and low noise levels were ABOVE: of the noise level. On Octopus airborne noise is cut by These two pictures quickly demonstrated, and much of the development illustrate the 4-8dB compared to a standard geared thruster with work has gone into proving durability, particularly in significant space electric motor in the thruster room, structure borne noise savings delivered by the most demanding service; vessels that spend much PM technology. is reduced by 6-12dB, while the noise to sea is 5-6dB less. of their lives in dynamic positioning (DP) mode with The thruster is also valued on board for its rapid response its constantly changing demands for thrust level and to changing loads. direction. Severe ice testing has also been carried out. Efficiency is high as no current is used for rotor Deck machinery excitation, and the level is maintained over the entire PM motors developed by Rolls-Royce are now being speed range, also helped by the absence of gear losses. applied to deck machinery. The electrical principles are Rolls-Royce research has demonstrated that for the same, with speed regulated by altering the frequency hydrodynamic reasons it is good to have a hub, of the electric power supply. But the configuration chosen rather than inward pointing sword blades. The hub in for powering winches is different. While a thruster has a production units also carries the rotor bearings, and forces large diameter, rather thin and narrow motor driving the are transferred to the static ring of the thruster by stays propeller on its periphery, the deck machinery motor has

12 a smaller diameter and is longer for a given power to suit BELOW: PM tunnel thrusters are currently the speed requirements. It drives the winch by a central available in two sizes. Those in service have shaft and high torque allows a small gear ratio, improving reduced airborne noise the dynamic response of the winch. by 4-8dB compared with a standard geared The characteristics of these PM motors are particularly unit. suited to applications that combine a need for high torque at low speed, sensitive control and rapid changes in pull and speed. Anchorhandling/towing winches for offshore vessels, escort winches for tugs, and trawl winches for fishing vessels are typical applications. Low pressure hydraulic winches from Rolls-Royce have for many years been market leaders when it comes to delivering this type of performance, and the new PM drive system will do the same for owners preferring an electric solution. For AHT winches, owners will be able to choose the Norwegian Epic first Rolls-Royce drive system that best suits their preference cruise ship to benefit and operating modes. The four systems are the standard LP hydraulic; LP hydraulic with the new E26 computer from PM thruster controlled valve system for extra sensitive control; a hybrid system in which the average loads are covered technology by variable frequency asynchronous electric motor with a supplementary hydraulic drive that handles quickly To help improve passenger comfort on board, changing loads; and the new PM electric drive. Norwegian Cruise Line has selected a Rolls-Royce PM PM motors have undergone extensive factory tunnel thruster to upgrade the propulsion package development testing, independent verification of IP onboard the 155,873gt Norwegian Epic, which can standard of waterproofing and now Class approval. accommodate up to 4,100 guests. The first installation in commercial service will be The PM tunnel thruster technology offers a trawl winch on a fishing vessel currently under numerous advantages over traditional tunnel construction for Prestfjord. RW thrusters, including significant reduction in noise and vibration, an increase in power output of around 25 per cent from the same size propeller, and is removable underwater, eliminating the need for dry docking. Jay McFadyen, Senior Vice President–Marine Services, Americas, says: “We are delighted that Norwegian Cruise Line is the first cruise customer to select our new PM tunnel thruster as an upgrade to an existing propulsion package. This innovative technology is suitable for a range of applications in both merchant and offshore vessels, where exceptionally low noise levels, high power output and rapid response to power demand will benefit operators, crew and, very importantly, passengers. “What we have seen so far through the experience of our first PM tunnel thruster in operation on the Rolls-Royce designed Olympic Octopus is that a PM motor thruster is quiet, efficient and durable. It is capable of running for thousands of hours in intensive DP mode, where rapidly varying loads and alternating thrust directions are the norm.” Other benefits of PM technology include the freeing up of space directly above the thruster where traditional tunnel thruster motors are located, and a symmetrical design that gives equal thrust to port or starboard. Models are currently available with 1,600mm and 2,000mm diameters.

13 TECHNOLOGY

Intelligence and

THERolls-Royce is at the forefront BRIDGE of bridge design, demonstrated by the Unified Bridge concept that went into service last year on the Stril Luna. But what does the future hold? Andrew Rice reports on the latest developments in intelligent bridge design

ABOVE: The oX Bridge concept not only provides the crew with smart workstations, but also uses augmented reality to provide much more detail of the vessel’s surroundings and potential hazards than visible to the human eye.

14 hree years in development, the Unified Bridge was first fitted to the UT 776 WP Stril Luna, owned by Simon Møkster Shipping, which entered service during 2014. It presents a physical working environment adapted to a person’s natural movements, a Tnew ergonomic approach to all the activity required on the bridge of a vessel. Watchkeepers are provided with a functional and easy-to-use human/machine interface with well-placed control levers and touchscreens to control systems that display their status in the most logical way. The Unified Bridge has already been ordered for a number of other UT vessels scheduled for delivery during 2015-16 and is a striking example of the role good design

15 TECHNOLOGY

plays in harnessing technology to improve operator ABOVE: The Rolls-Royce Unified performance, simplicity and safety. Bridge that went into service during 2014 ›› Rolls-Royce, working with the VTT Technical Research on the offshore vessel “THE NEED IS FOR Centre of Finland and Aalto University of Finland, is Stril Luna. INTELLIGENT SYSTEMS now setting out a vision for a future ‘intelligent bridge’ ABOVE RIGHT: Iiro Lindborg, that could be a reality by 2025. It is known as the Future Development Project THAT CAN RUN Manager for the oX Operator Experience Concept, or oX. It offers the crew concept. THEMSELVES, WITH smart workstations, which automatically recognise individuals when they walk on to the bridge, and adjusts THE CREW BECOMING to their own preferences. SUPERVISORS”

Enhanced ergonomics It is just one example of ship intelligence. It not only provides the crew with smart workstations, but “The need is for intelligent systems that can run also augmented reality bridge window displays that provide themselves, with the crew becoming supervisors, much more detail of the vessel’s surroundings and potential concentrating on managing the exceptions when they hazards than normally visible to the eye. The system can, for arise,” says Iiro Lindborg, Development Project Manager example, identify sea ice, tugs and other vessels that may for the oX concept. not be visible to the crew, especially if they are on the bridge “The supervisory role provides the necessary input of a large container ship. of human experience machines just don’t have. The The oX concept is a response to the increasing technologies that enable experts on land to be inserted complexity of equipment now being fitted to ships. into problems onboard already exist, so developing As crew levels reduce and automation levels increase, technologies such as augmented reality are likely to there is a need for smarter interfaces to help them. play a bigger role.”

16 Digital To get a better view of the bridge, watch the video on our digital edition by downloading the In-depth app from iTunes or Google play

A notable focus is applicability to unmanned vessels, ABOVE: Rolls-Royce, parameters gives us a lot more insight into what brought working with the VTT which is where the industry could be headed if technical, Technical Research them about. We have deployed data logging on a variety Centre of Finland and legal and cultural challenges can be overcome, with Aalto University in of vessels, but most experience has been with high value proven safeguards for communication channels. Finland, is setting out offshore vessels. On one anchorhandler, we are logging a vision for a future Today, most onboard equipment and sub systems intelligent bridge some 15 gigabytes of data each day. that could be function in isolation. Rolls-Royce is planning to take the lead a reality by 2025. “This approach reflects the way Rolls-Royce operates in changing that. Ships are becoming much more complex. in the aerospace sector, where some 13,000 gas turbines There are already ECDIS and dynamic positioning, health are operating, with nearly 75 per cent covered by long- monitoring and decision support systems. Operating the term service arrangements. We have moved engine ship can be aided by automated reporting. maintenance from the operator back to the manufacturer, What these technologies have in common is that they so there is a lot of real-time monitoring going on. So we automate tasks previously done manually, a trend that is have a clear view of how the engines are operating and set to continue as availability of competent crew declines. any decisions regarding managing operational issues or Finding new and improved ways of doing things is vital maintenance can be made very quickly.” for continued safe operation and ultimately profitability. In both aviation and marine, this data can be used as Intelligent ship systems will help make sense of the vast input for R&D activities. The performance of new products amount of information coming from multiple sources. can be evaluated in the field, and it can be used in the They will be capable of determining what information is vessel design process to optimise propulsion system important and requires action and what is just routine configurations, based on actual operational experience. data, which can be stored and used to build a detailed For the marine sector, Rolls-Royce is undertaking research picture of the vessel’s operating profile. in developing sensors for harsh environments which can communicate across watertight boundaries. Harnessing data “We are entering a truly exciting period in the history The Marine Services team, headed by Andy Marsh, of shipping, where technology and in particular the smart President, undertakes the task of transforming this data use of Big Data is going to drive the next generation of from different sources into commercially viable systems. ships,” adds Iiro Lindborg. ”Over the next ten to 20 years “We already collect a lot of data onboard – the trick we believe ship intelligence is going to be the driving is pulling it together to extrapolate trends,” says Andy. force that will determine the future of the industry, the “Detecting unusual stresses in thrusters is useful, but types of ships at sea, and the competence levels required combining it with sea-state and other environmental of tomorrow’s crew.” AR

17 TECHNOLOGY

TAKESelecting YOUR the right propulsion system for a PICKcruise vessel means balancing of performance, purchase price and through life costs. The Rolls-Royce Blue Ocean team has developed a range of options to make selection simpler, leaving operators free to concentrate on their ship design and passenger experience

ne of the goals of the Blue 40 years,” says Oskar Levander, VP and hotel loads. This provides service Ocean team is to design Innovation Engineering & Technology. speeds of up to 21 knots and maximum propulsion systems that “As we have such a wide range endurance at 16 knots. In each case, are matched to individual of power and propulsion products, power is provided by Bergen or MTU vesselO profiles, and give customers we can package them into systems engines, or a mix of the medium-speed clear options so they can select the that accommodate most customer and high-speed engines driving right system to suit their needs. preferences for vessels of this size, Rolls-Royce thrusters or propellers. As system designers will tell you, which can be tailored to exact there are many trade-offs in arriving requirements. We will provide the Four propulsion options at the optimum propulsion system equipment and machinery layout for After completing ten system solution. What is the priority for the bottom two decks. These systems trade-off studies based on the the customer? Is it performance, can then be inserted onto the selected requirements for known adventure reliability, first cost, fuel consumption ship design to speed up the design cruise routes in both the northern or through life costs, and what is the process. This leaves the interior and and southern hemispheres , four expected life of the vessel? These naval architects free to concentrate systems capable of being efficiently and many other factors impact on on the look and feel of the passenger integrated into any suitable cruise the investment decision and the areas in the ship.” ship platform were selected. value it represents. The systems are designed to suit “The concept introduces the idea “Designing systems that are vessels from 5,000 to 20,000gt, with of transferable technical spaces into matched to the vessel and its design between 200-300 passengers, so any architecture,” says Esa Jokioinen, intent is something we have been powers ranging from 4-11MW have Head of the Blue Ocean team. “These doing in the offshore sector for over been selected to cover propulsion systems are capable of meeting most user requirements, whether the priority is a low initial procurement cost or a system that delivers the lowest through life costs. In combination with a low resistance hull form, they offer good fuel efficiency and effective manoeuvring, with the choice depending on the type of cruise itinerary and the operator’s preference.”

The Balanced System: Twin Promas with CP propellers and hybrid shaft generator PTI/PTO This is reliable, efficient, conservative and offers relatively low first costs. Main propulsion is provided by two 2,665kW Bergen C25:33 L8P engines each driving a CP Promas system through a reduction gear with hybrid shaft generator (HSG), so the main engines can be used to provide electrical power. Two 1,560kW MTU 12V4000

18 BALANCED COMPACT

A trusted arrangement that provides an excellent A flexible arrangement that provides low investment balance of economy and efficiency. cost, small footprint, and yard-friendly installation.

Machinery: Machinery: Mechanical Hybrid High Speed Diesel Electric Propulsion: Propulsion: Twin Promas Twin Azipull Shaftlines

1 3 Digital View an animation of the different options available by downloading the free In-depth app from iTunes or ULTRA CLEAN Googleplay LIFECYCLE

Pure gas machinery coupled with advanced An elegant pairing of propulsion equipment and machinery provides propulsion equipment provides the highest very high operational efficiency and low lifecycle cost. operational efficiency and lowest emissions. Machinery: Machinery: Medium Speed Diesel Electric Medium Speed Diesel Electric Propulsion: Propulsion: Large Area Propeller Large Area Propellor with Twin Azipull with Twin Azipull

4 2

M33S generator sets supply the costs despite having the highest ABOVE: The four three weeks’ cruising. propulsion systems are switchboard. This configuration allows initial cost. A fully electric system, contained in the lower All machinery and propulsion two decks and are the selection of mechanical, electric or power is provided four 1,843kW matched to suit packages can be complemented hybrid modes for optimal performance Bergen C25:33 L6A diesel generators. the needs of smaller with additional Rolls-Royce products vessels in the 5,000 in all operating conditions. A single shaftline drives a large area to 20,000gt range for such as stabilisers, mooring winches the specialised cruise CP propeller, which is flanked by sector. and a Unified Bridge. They are The Compact System: two electrically driven Azipull 120 integrated to perform efficiently Twin Azipull with full thrusters, which provide propulsion together and are supplied with a electric propulsion as well as manoeuvring, therefore range of Rolls-Royce automation and This is installation friendly with a there is no rudder. A central propeller control equipment. small footprint and low weight. It is normally used to provide the For the owner, full systems also has the lowest capital cost of necessary thrust for top speed. integration delivers advantages the four systems. Power is provided The Azipull units can be used for like competitive operating and by four 2,080kW MTU 16V 4000 M33S lower speed cruising for improved investments costs, with optimised gensets for a total installed power of economy and provide vectored performance. Through life support 8.4MW. As the generators are small thrust at the stern, and with a is also simplified. For the shipyard, and there are no long propeller 1,000kW bow thruster give a high design work is reduced and the risk of shaftlines, there is significant level of agility. variance from the design requirement flexibility in where they can be sited. is minimised due to more accurate This also frees up valuable space for The LNG option performance predictions. other purposes, giving the designer The Lifecycle system is also available more options. The 2,458kW Azipull with Bergen LNG engines of the Larger platforms units provide the necessary steering same size and power together with Rolls-Royce integrated systems are and manoeuvring control so no the complete gas system. Space not limited to this size of cruise ship rudder is required. for the LNG tanks is created by and are available for vessels up to lengthening the vessel and inserting 60,000gt. Other products suit all The Lifecycle System: a new mid-ship section at the vessel sizes. AR Centre line propeller forward main fire bulkhead location. with wing thrusters This section can house four vertical FIND OUT MORE This delivers the lowest ownership LNG tanks with sufficient capacity for [email protected]

19 CUSTOMER FOCUS Helping

HANDSLast year, Rolls-Royce officially became a supporter of Mercy Ships, an international charity with the mission to increase global access to healthcare through a fleet of hospital ships. A comprehensive service for the equipment on board the Africa Mercy is provided, as well as access to training facilities and financial support

ercy Ships brings free, quality medical care to the poorest nations of the world through its fleet of hospital ships, the largest of which is the Africa Mercy, a converted rail ferry. It is also the largest non government-owned hospital ship in the world. Onboard are five operating theatres, recovery andM intensive care and low-dependency wards, which make up a total of 82 patient beds. Surgical capacity is about 7,000 interventions a year, and specialist equipment includes CT scan/X-ray suites and laboratory services. Satellite communications are used for consultations with pathologists in other countries and to access additional specialist support. The partnership with Rolls-Royce will help ensure the continued, uninterrupted operation of the Africa Mercy. As Andy Marsh, President of Marine Services, says: “Rolls-Royce is committed to making a positive difference to the communities in which it operates. This partnership with Mercy Ships is an opportunity to use our marine equipment expertise and our dedicated people to enhance the tremendous work Mercy Ships performs, bringing medical support to the underprivileged around the globe.” Russ Holmes, Mercy Ships Director of Corporate Relations, says: “Partnering with Rolls-Royce gives us the opportunity to keep our hospital ship Africa Mercy maintained to the highest standard so that we can continue providing healthcare to the poorest of the poor. It also gives Rolls-Royce employees the chance to be part of what we do.” At 16,572gt, the Africa Mercy is currently the largest civilian hospital ship in the world. It is 152m long with a beam of 23.7m and has a crew capacity of 474. Four engines provide more than 12MW of power for propulsion and ship services. Built in 1980 in Elsinore, Denmark, the former rail ferry Dronning Ingrid was built for Danish State Railways. It was purchased by the charity in 1999, when the Africa

20 ABOVE: Hospital ship Africa Mercy, a converted rail ferry, is home to over 400 people and started bringing medical services to people in Africa in 2007.

LEFT: IMAGE CREDIT: MERCY SHIPS MERCY CREDIT: IMAGE A patient recovers on board Africa Mercy.

Mercy project started. Cammell Laird Shipyard, which Islands. It was the first time Rolls-Royce engineers had later became A&P Shipyard on Tyneside in the UK, worked on the vessel since the partnership began. undertook fitting out. The ferry’s large train deck During the eight-month stay in Madagascar, Mercy made it a good choice for conversion into a hospital. Ships estimates that it will provide approximately 1,700 When it commenced service in 2007, it brought in surgeries for adult and child patients on board and a greater capacity than the three earlier Mercy Ship treat approximately 8,000 at a land-based dental clinic vessels combined. renovated for that purpose. In addition to surgeries, As 75 per cent of the world’s population live within ship-based teams serve local villages by providing a 100 miles of a port, modern hospital ships can provide range of services to increase the health and wellbeing in some way for the people who lack access to medical of the local population. Health education, mentoring care, clean water and reliable electricity. of local healthcare professionals and agricultural training Based in West Africa, the Africa Mercy visits different are offered as well. countries at the specific invitation of the host nation’s The vessel has meeting and work spaces for the average government. Before Africa Mercy departed for its eight- crew of 450. Accommodation includes 26 family cabins, 25 month visit to Madagascar, the ship’s bow thrusters were couple/twin cabins, and the rest are one, two, three and overhauled by Rolls-Royce while in drydock in the Canary four-berth cabins. AR ›› 21 CUSTOMER FOCUS A master OF MERCY What does it take to be the Master of during the development phase of Africa Mercy. a unique vessel and be responsible for We have a son, who thrives onboard in ›› more than 450 people? The Academyz, along with about 43 In-depth put a few questions to Timothy other children. Tretheway, Master of Africa Mercy Why do you do what you do? Where did you get your Many people dream of changing maritime experience? the world, of helping others have As a life-long sailboat sailor and a better life, yet for many they do racer, I was on the water at an early not see how their profession or age and later learned navigation skill can be a benefit to a poor while racing and delivering person suffering unimagined pain sailboats. As I began my working or disfigurement or blindness. I was career, I worked in the development the same. I also was exploring my of ports and marinas, involving aids personal faith in God and wondered to navigation, dredging and marine how I might be able to help bring hope construction, and also progressed my and healing to others. maritime licences and training. I discovered that my maritime skills could provide a platform for helping such people, How did you get involved with Mercy Ships, and it has been my privilege to have done so now and what are your responsibilities? for 28 years. In addition, it really comes down to the In the mid-1980s, I heard that the Mercy Ships original BRINGING HOPE human beings we see each day who might be trapped in the flagship, the Anastasis, was seriously short of seafarers, and so I darkness of blindness, or incapacitated with deformities of the Timothy Tretheway, volunteered as a seaman. I was impressed by the mission Master of Africa Mercy, limbs or daily living in pain from a host of maladies. As a result, says it is a privilege to and method of the ship and crew, and deeply moved by use his maritime skills I am continually refreshed to witness the blind see, the lame personal experiences with the people the ship came to to help bring hope walk, and hope made tangible to the poor. What could be a and healing to others. serve. I felt that, although I did not have the skills to physically (Image credit: better legacy? Mercy Ships) transform a life, I could move and maintain a good platform for those who could. So I made the commitment How is Rolls-Royce support helping? to focus my career toward helping suffering people by The overhaul work and spares for our bow thrusters last serving in Mercy Ships. year has improved our safety on Africa Mercy. Many ports we I served in many capacities over the years, including able- visit have little or no tug support. We therefore need every seaman and all the different officer levels. I had the pleasure advantage when manoeuvring, and our newly overhauled of being a training officer for some time and enjoyed seeing bow thrusters and high-angle rudders are a huge advantage. some of our diverse and often untrained crew, many from In addition, we are currently in a port exposed to tropical developing nations, become competent seafarers and officers. cyclones and related surge conditions. We use the bow At various times, I have been the master or senior deck thrusters to assist us in maintaining position at our berth in officer on most of the ships in the Mercy Ships fleet and heavy surge conditions. became Master of Africa Mercy in 2008. It has recently been announced that Africa Mercy will return I met my wife while serving as chief officer on our previous to Madagascar in August 2015 after a short refit in Durban, flagship in Spain during a refit, and we married a few years later South Africa.

“I HAD THE PLEASURE OF BEING A TRAINING OFFICER AND ENJOYED SEEING SOME OF OUR DIVERSE AND OFTEN UNTRAINED CREW, MANY FROM DEVELOPING NATIONS, BECOME COMPETENT SEAFARERS AND OFFICERS”

22 from surgery, releasing onboard beds. Here it is an unused building, renovated by Mercy Ships, and it will become a legacy for the locals when the Africa Mercy leaves. Next door, another building has become a dental clinic, a novelty as there are very few in the whole country. On day one the team saw 40 patients, but carried out 139 tooth extractions!

DAY 3 Today I saw patients who have already been assessed in a reception point on the dockside and have an appointment for surgery. I did rounds with Maxillofacial Surgeon Dr Gary Parker, a remarkable man. He signed up for three months with Mercy Ships 28 years ago, after medical school before starting ‘real work’, and has never left. He met his wife and had two children who have spent their entire lives onboard, the eldest only leaving last year for university. Life-changing I met a young girl with a disfiguring large tumour under her chin, naturally very shy and she uses a shawl to hide it. Although the tumour is benign, it will continue to grow – eventually restricting airways. In the west, dentists find these tumours before they grow – not so JOURNEY here. I am dressed in scrubs and invited to witness this To help Rolls-Royce employees gain an insight life-changing operation. of life onboard Africa Mercy, Crystal Kuan, Sales DAY 4 Today I joined recovering patients on deck to and Marketing – Marine Services, joined the enjoy the view and fresh air. One girl has come in for vessel in Toamasina. Here are some excerpts surgery on her bowed legs, normally caused by malnutrition, so I am able to pull her along in a wagon. I from her blog: take a video of her playing and she howls with laughter – seeing herself on video for the first time is the funniest thing. Another little boy had been operated on so he DAY 1 As a guest, I get one of the more luxurious cabins. could use his mouth again, releasing him from a life For crew, jobs are posted with a ‘stay length’ and this eating soup. influences accommodation. The largest is a ten-berth There is a fully certified school called The Academy, cabin. For example, receptionists and kitchen staff with 16 full-time teachers to educate the 43 children IMAGE CREDIT: AMANDA WILDER require less ramp-up time, so have a minimum living onboard. Programmes are tailored to the UK or US commitment of three months. Whereas a nurse or education system, up to university entry. Finished the anaesthetist will require more familiarisation time, so day with a career talk to 16 teenagers, which was an eye the minimum stay is ten months; for senior roles it’s ABOVE: Crystal Kuan opener. They are so smart because they have seen so interacts with Tonny two years. The longer your commitment, the bigger [top] and Erissa [below] much of the world, but said there are some things that the cabin you get. whose bowed legs you don’t realise you don’t know being raised on a ship – Mercy Ships volunteers I’m so impressed by the people onboard. It takes about were able to correct. such as, for example, how to use an ATM! 400 crew members and 200 local day crew to keep this hospital ship running. The day crew are employed to give them work experience and to help with a range of support activities, including translation. Some are fluent in Malagasy, Mandarin, French and English. I am amazed that the volunteer crew have to pay for their own room and board in addition to giving their time, and that does not result in a lack of staff. They rely on support and sponsorship from family and friends for costs that vary, but it’s roughly $700 USD (£456) a month for cabin and board. Mercy Ships understands everyone is giving their all, so do their utmost to look after the crew.

DAY 2 At every port location, the ship partners and works with the local hospital as a location for their HOPE Centre (Hospital Out-Patient Extension). This is needed to provide secure shelter for patients awaiting or recovering

23 UPDATES

24 CELEBRATING

OF50 AZIMUTH YEARS THRUSTERS

he first azimuth thruster In the half century since the first was largely made up from tractor and Aquamaster® azimuth thruster was vehicle components, delivered, the technological advances and started life as a and differences of today’s designs diversification for the THollming shipyard in Rauma, Finland. make it virtually unrecognisable The yard had been established to build vessels as war reparations to the Soviet Union, and was looking for something to even out market fluctuations. Their first product volumes were small, between was a steerable propeller with a two and ten units per year deck-mounted diesel engine, in sizes from 50-200hp. which was installed on a The market was there, but hopper barge called Palko, the main difficulty was also devised by the yard. sourcing components. The That was half a century first exported units went ago, and the beginning of to Germany, then Sweden product development that specified azimuth units for has grown in size and scope to propelling road link ferries. become a key part of today’s In the UK, Yorkshire Dry Dock built

Rolls-Royce propulsion portfolio. ABOVE: The Contaz many small coastal cargo vessels, At that time the principle of the thruster range brought each with two 400hp units. As the with it new levels of azimuth thruster was well known. efficiency, with low export market grew, a suitable name levels of noise and John Ericsson, the innovator of many vibration. was needed for the product, and it technologies in the 19th century, had evolved over time to be known as patented a deck-mounted outboard the ‘Aquamaster® azimuth thruster’. engine. Other patents were issued Aquamaster® remains a valued in the US and UK in the 1870s and registered trademark of Rolls-Royce. demonstrated as through hull units By 1975 thrusters were offered in on a large scale. During the Second four sizes, from 100 to 800hp. The

World War, barges were equipped with LEFT: The largest order market outside Europe had grown over-the-stern thrusters with deck- for UUC underwater as well, expanding to include the mountable thrusters mounted engines. But there was not to date was for the US, Canada and Japan, while sales innovative Allseas yet a convincing commercial demand. heavy lift vessel volumes were growing rapidly Pioneering Spirit. The This emerged in the 1970s and has picture shows the 13 and marketing companies and widened ever since. thrusters being loaded agencies were being set up for the voyage to the For the first few years, production buildyard in Korea. around the world. ››

THE PRODUCT HAS GROWN IN SIZE AND SCOPE TO BECOME A KEY PART OF TODAY’S ROLLS-ROYCE PROPULSION PORTFOLIO

25 UPDATES

Research and ›› development THE FIRST AQUAMASTER It was clear that the market was interested in bigger AZIMUTH THRUSTERS azimuth thrusters. The WITH POWERS IN EXCESS problem was finding durable large bevel gears and the OF 10,000HP WERE other components needed to DEVELOPED IN THE EARLY handle the high powers. Special gears could be prohibitively 1990S, THE INITIAL expensive to buy, and other APPLICATION WAS design constraints might pose a ICE-STRENGTHENED long-term maintenance cost. A significant advance came ARC 1 UNITS at the beginning of the 1980s with the design of the first unit Powerful to be rated at over 1,000hp. This At the other end of the size was the Aquamaster® 1600. The spectrum the first Aquamaster® Finnish oil company Neste ordered azimuth thrusters with a power three tugs equipped with these rating in excess of 10,000hp were thrusters and these vessels became developed in the early 1990s, the a good reference in the years initial application being a very that followed, not only for demanding one, ice-strengthened reliability but also for their ARC 1 units. Two thrusters manoeuvrability. per ship were supplied The quest for greater to the multipurpose efficiencies led to the icebreakers Fennica and Aquamaster® CRP, an azimuth Nordica, providing both thruster with two contra- main propulsion and excellent rotating propellers close manoeuvring in open water or together so the aft propeller thick ice. The two vessels are still recovered swirl energy from operating in the same way today, the leading one. It was given providing icebreaking services in the the name Contaz. ABOVE: The quest for Baltic during winter and acting as greater efficiencies The result was an improvement The first CRP thrusters were delivered led to the successful offshore support vessels in summer. Aquamaster CRP, an in thrust and vessel speed, with to a road ferry operating in Turku, azimuth thruster with The Aquamaster® business was a corresponding decrease in fuel southern Finland. It operates in ice two contra-rotating restructured and enlarged several propellers, which was consumption. during the winter. named Contaz. times in the years following its

Ice-strengthened models The largest order for UUC rated at 7,500kW with underwater mountable DNV Polar 10 ice class thrusters to date was for the were fitted to the ice- innovative Allseas heavy lift breakers Fennica and vessel Pioneering Spirit. Nordica in 1993. Over 1,000 UUC thrusters have been delivered to date.

Steerable azimuth thruster no 1 went into service in May 1965, propelling the mud hopper barge Palko with 60kW of power. UUC Allseas

Large underwater mountable thrusters, with over 5,000kW of

Ice-strengthened models Ice-strengthened power, were developed for drills ships and

Underwater mountable units mountable Underwater semi-submersible rigs. Steerable azimuth thruster no1 thruster azimuth Steerable

26 LEFT: The ice breakers birth in the Hollming yard, most Fennica and Nordica were fitted with significantly when it was merged with thrusters rated at 7,500kW with DNV the Rauma Repola deck machinery Polar 10 ice-class. business. The enlarged Aquamaster® business was acquired by Vickers plc in 1995 and was combined with Kamewa propulsion products manufactured in Sweden. This combination of experience led to the development of the UUC range of underwater mountable thrusters, with the first being delivered for drill rig applications in 1998. These robust thrusters, designed primarily to operate in dynamic positioning (DP) mode, BELOW: UUC underwater mountable can be removed and installed without thrusters are removed and exchanged during drydocking, an important feature as a drill rigs normal most rigs operate in remote locations. docking period. Today they are fitted to over 70 per cent of the world’s semi-submersible drilling rigs and drillships.

New developments From 2000 the thruster and deck machinery product lines manufactured in Finland and Sweden were integrated with other Rolls-Royce products manufactured in Norway. The range of azimuth thrusters became the broadest in the business and development continued. In 2002 the first Azipull units, a ’pulling’ azimuth thruster, were retrofitted on the offshore vessel Havila Tampen. Designed for maximum propulsive efficiency, with a hydrodynamically efficient shape, Azipull units are suitable for higher speed applications and for continuous service speeds of up to 24 knots. Sea trials showed a 20 per cent efficiency gain with better course keeping characteristics. Azimuth thrusters and tugs were an ideal The conventional azimuth thruster match conferring new levels of precision range (US) with L or Z drive has also manoeuvrability. grown in power, with nine basic frame sizes now covering the power spectrum from 500-5,000kW. Modular construction means customers can select three installation options with ducted or open propellers,

The introduction of the controllable, fixed pitch Azipull pulling thruster and contra-rotating. has improved propulsive The introduction of the efficiency for vessels with A retractable range is suitable for Contaz thruster range a high top speed, and has brought with it new been selected for a number auxiliary propulsion for DP vessels Contaz thruster range thruster Contaz levels of efficiency with Thruster Pulling Azipull of commercial vessels where and take home propulsion, and PM low levels of noise and precise manoeuvring vibration. Tugs and Thrusters Azimuth is also important. thusters will soon be added. Over the past five decades more than 8,000 azimuth thrusters have been delivered. RW

27 UPDATES

planet is covered by water and that significant high-grade mineral resources have been identified on the ocean floor, the mining industry is prepared to move offshore in much the same way that oil and gas industry moved offshore 40-50 years GOLD ago,” says Mike Johnston, the CEO of Nautilus Minerals, the Canadian mining contractor that will charter the world’s first seabed mining Rolls-Royce propulsion equipment is set to power support vessel. DIGGERan innovative seabed mining ship, opening “Together with the scientific community, we have carried up a new market for the shipping industry out extensive research into understanding the environment at Solwara 1 and have developed mitigation strategies to reduce the impact of mining operations, in hen China’s Fujian BELOW: Six Bergen valleys and plains of the seafloor and particular the fully enclosed riser B33:45 generator sets Mawei shipyard will provide a total higher ore concentrations. and lifting system that ensures power output of nearly delivers its high- 30MW. With selective What’s more, the cost of the copper resource taken from catalytic reduction, the end production vessel is Tier III developing a seafloor mine is the seafloor never comes in support vessel compliant and meets significantly less than a land- contact with the seawater above the American Bureau to Dubai-based of Shipping’s (ABS) based equivalent, due to reduced the mining operation.” Comfort Class Marine Assets Corporation in 2017 notation. (Six-cylinder machinery and development Once bulk cutters have cut the W B33:45 illustrated) for deployment under charter to costs. There is no direct impact seabed rocks to manageable sizes, the Solwara 1 site in the Bismarck on communities and mining the mineralised slurry is pumped Sea, it won’t be the ‘black stuff’ this infrastructure can be easily relocated. though the fully-enclosed riser pipe revolutionary vessel will help exploit, Yet despite these seemingly to the PSV on the surface, where the but instead will set its sights on favourable factors, together with ore is separated. something much more alluring – international declarations permitting The Fujian Mawei yard has now gold. the mining of the seabed for the started work on the ShipTech The 0.11km 2 Solwara 1 project, “benefit of mankind”, falling metal Solutions-designed vessel. Based on 30km offshore Papua New Guinea prices and technological infancy has a large offshore construction vessel, (PNG) and the first ever deep-sea put large-scale seabed mining on the 227m-long, 40m-wide first-of- mine, is expected to open up a hold – until now. a-kind vessel will be built to ABS previously unexplored frontier Today, perhaps a consequence of Comfort Class rules. for the extraction of base and the recent technological advances To accommodate heavy lift precious metals and, potentially, made in offshore oil and gas equipment topside, the 68,000t a lucrative new market for seabed exploration and production, the vessel’s deck has a 1,000m2 working mining vessels. technology is now readily available area strengthened to 7.5t/m2 to An offshore gold rush has long to make seabed mining economically accommodate one 200-tonne subsea been mooted given the rich and environmentally viable. crane, a 100-tonne ship-to-shore abundance of minerals in the peaks, Regulations are also being crane and two 20-tonne deck cranes. developed for this new industry by Below deck, ore storage holds a number of countries. are arranged amidships. Ore will be “Given that 70 per cent of the transferred to incoming handy size bulk carriers. All of the below-deck mining equipment will be installed in the 180-passenger capacity vessel to minimise equipment integration on delivery in 2017. Propulsion equipment will be supplied by Rolls-Royce and is arranged in a diesel-electric configuration, based around the new Bergen B33:45 medium-speed engine range producing 600kW per cylinder. INSET: MAC will take delivery of the world’s first seabed mining vessel from Fujian Mawei in 2017. (Image courtesy MAC)

“WE ARE PLEASED TO BE AT THE FOREFRONT OF A NEW CHAPTER IN UNDERWATER EXPLORATION”

Six nine-cylinder 5MW Bergen oil and gas sector, we look forward says: “We are not so familiar with MIKE JOHNSON B33:45 gensets with SCR technology to working with Marine Assets the mining industry itself, but since Mike Johnson, CEO will feed consumers that include Corporation and Nautilus Minerals becoming involved in this project, Nautilus Minerals: “The company will charter a number of Rolls-Royce thrusters in enabling them to become first it is certainly apparent that there is the seabed mining – three 3,000kW underwater movers in the extraction of valuable huge potential in subsea mining. support vessel”. mountable azimuth thrusters astern, minerals from the seabed.” “Nautilus is the market leader and two 2,000kW tunnel thrusters The vessel will operate under a in this segment and I believe and two 3,500kW retractable five-year time-charter with options to Solwara 1 is the first project that has thrusters at the bow. extend or purchase the vessel. It will actually come off the drawing board. The propulsion arrangement serve as the operational base for the Obviously these water depths are meets DP2 requirements with a joint venture (Solwara 1 JV), formed unknown territory for most of us, service speed of 12 knots. by Nautilus and the Independent but site surveys and sampling have John Knudsen, Rolls-Royce, State of Papua New Guinea’s proven that the subsea mining President – Commercial Marine, nominee, Eda Kopa (Solwara), a wholly sector can be extremely lucrative says: “This multi-engine delivery owned subsidiary of Petromin PNG compared to land mining, with to long-standing customers Fujian Holdings, which has taken a 15 per mineral content per tonne of ore Mawei and MAC is a major step for cent stake in the Solwara 1 mine by considerably higher. our new medium-speed engines contributing $120 million towards “For MAC, this is very exciting to and we are exceptionally proud operational costs. be building a ‘world’s first’ again, that the first Bergen B33:45 gensets Nautilus expects that mining and we have a long history with have been selected to power this the Solwara 1 site will take three Rolls-Royce and Bergen pioneering ship. They offer a 20 per to four years, with an annual yield equipment, so cent increase in power per cylinder, of 1.3 million tonnes of ore. Having we know the while fuel consumption, emissions a moveable infrastructure means vessel will and through-life operating costs are as other prospective deposits are perform well.” substantially reduced. identified, the mining operations can PW “Deep-sea mining is an exciting be moved to the new site. new industry and we are pleased to “Our goal is to set the standard be at the forefront of a new chapter in how companies extract minerals in underwater exploration. Demand from the ocean and ensure the for natural resources continues to continued sustainability of this rise as developing countries emerge valuable resource for the future,” says and land resources becoming Mike Johnston. increasingly stretched. With our Mark Reeves, Marine Assets extensive pedigree in the offshore Corporation’s Chief Operating Officer, UPDATES

BALANCINGTHE ACT

ydrodynamics is at the heart of Rolls-Royce Rolls-Royce designers deal with vastly differing needs when it comes marine activities. A large to propeller design, depending on the customer’s specific operating number of products in conditions. Decades of experience studying hydrodynamic and the portfolio involve moving fluid, therefore cavitation efficiency are critical in meeting those requirements a largeH knowledge base has been built up constrained by the ship designer,” As one notable naval architect said in propeller design, a number of says Chief Hydrodynamicist Robert to me once, without a good propeller, azimuth thruster designs, tunnel Gustafsson. “This can mean the you don’t have a good ship”. thrusters and waterjets. propellers have to be a smaller diameter Gaining a deep understanding Not only must the hydrodynamic than the optimum, or with insufficient of hydrodynamic issues requires a performance of the propulsor be clearance between the blade tip and lot of experience and historical data defined, the complex interaction the hull. Cavitation performance is also on which to draw. The Rolls-Royce between the hull and rudder has a limiting factor, strongly affected by Hydrodynamic Research Centre to be fully understood for good the inflow the hull generates to the ABOVE: A propeller has been undertaking detailed design that was performance to be achieved with propeller. As yet the capability does not rejected due to erosive hydrodynamic studies of propulsors the minimum noise and vibration, exist to design it out of any ship and cavitation. for over 70 years. More than 1,500

particularly important for cruise and propulsor design, but its effects, which BELOW: Propeller propeller designs have been model tip vortex cavitation passenger ships, super yachts and can cause vessel damage in extreme can be clearly seen in tested to date, and about 40 are naval vessels. cases, must be fully understood for any the test tunnel, with undertaken each year. hub vortex cavitation “The propeller designer is often ship design to be a success. barely visible. Over the last decade, computational fluid dynamics (CFD) and numerical methods have advanced at a rapid rate and brought further improvements. Using this bank of hydrodynamic and CFD data, a design system known as ‘Propcalc’ has been developed, automating and integrating optimisation and CFD analysis tools into the Rolls-Royce design process, making it possible for a designer to arrive at a preliminary blade design very quickly.

Efficiency What is good performance in context of propeller design? Most people would say good efficiency with low fuel consumption and, in most cases that is correct. But for ice breakers,

30 different operational parameters the inception point of the various types “WITHOUT A GOOD PROPELLER, of cavitation can be determined and YOU DON’T HAVE A GOOD SHIP” mapped. For each type of cavitation, the points are combined to form blade strength and reliability could be and a lot of cavitation, with the limit curves, then another curve top and for cruise vessels and yachts, resulting risk of erosion with high representing the operation of the it’s normally onboard noise levels. For noise levels. As no shipowner vessel is overlaid. The intersection naval vessels that need to operate wants a propeller that initially has point between this curve and the silently at high speeds, it’s cavitation very good efficiency, but after a propeller cavitation curves identifies inception speed – the speed at short time experiences cavitation the inception speeds. which they can operate before the erosion or high vibration levels, Fig 1 is an example of a cavitation propellers produce any cavitation and two types of comparative model inception diagram with only two radiated noise, so making them much testing is the best way forward. types of cavitation shown. To create easier to detect. First is a towing tank test the diagram the cavitation tunnel Cavitation comes in many forms, (resistance and propulsion) where must be set to a certain cavitation the main ones being suction side power consumption is measured. It number (σ). This number is set by sheet, blade root, tip vortex, hub should be followed by a cavitation changing the pressure in the tunnel, vortex and propeller hull vortex test, where cavitation performance the water velocity is normally kept cavitation. The balance between and pressure pulses can be validated. constant. efficiency and cavitation is just one The standard test is designed to For each change in number, the of the balancing acts for the designer study fully developed cavitation, to advance ratio (J) the measure of – several operating conditions of the determine if it is erosive and the noise the propeller blade angle of attack propeller must also be considered. it generates. As there is a step-change is varied. The start point is a low The target is to achieve in the noise level a non-cavitating propeller shaft speed (high J) with no the lowest possible power propeller produces and its cavitating cavitation on the suction side. Speed consumption in the towing tank counterpart, it is necessary to find the is then increased to the point when test at model scale. But this can cavitation inception speed (CIS). This tip vortex cavitation starts. Repeating CAVITATION mean other factors such as is the point where cavitation is barely INCEPTION SPEED the process, but this time from a vibrations on board, radiated noise visible. But the change in noise level DIAGRAM high shaft speed, the speed at which levels, risk of corrosive cavitation, happens quickly, as soon as cavitation the cavitation starts on the pressure and fuel consumption at full scale. starts, so even a small amount gives A cavitation inception side of the blade is identified. For a diagram with only Cavitation performance rise to a significant increase in noise. two types of cavitation complete cavitation test, the process shown. In this example, and noise levels are normally Identifying CIS requires a special test the CIS is 17.8 knots. is repeated for all types of cavitation. contradictory to high efficiency. to find incipient cavitation and starts It is the first intersection between the ship curve High propeller efficiency often with the propeller completely free and the cavitation curve for the suction Interactions results in high-pressure pulses of any type of cavitation. By varying side of the blade. Having an in-house hydrodynamics facility enables areas of concern to be 6 studied under controlled conditions. One particular area is propeller and Suction side tip vortex rudder interaction, which can lead to 5.5 cavitation damage over part of the Pressure side tip vortex rudder blade. 5 Flow from the propeller slipstream approaches the rudder with a 4.5 swirling motion having both an axial and rotational component, 4 which can produce cavitation on σ the rudder at any angle. Solutions 3.5 have been developed that include Inception speed 17.8kn changes to rudder shape in three 3 dimensions, and better integration of the hull, propeller and rudder. All 2.5 these factors are taken into account when perfecting the Promas system designs for individual vessels. AR 2 FIND OUT MORE 1.5 J Email robert.gustafsson@ 0.9 0.95 1 1.05 1.1 1.15 1.2 1.25 1.3 rolls-royce.com

31 UPDATES

A STAR

The selection of Promas by Viking Cruises and Fincantieri for excellent inflow to the propellers, as well as good clearance between ISa new breed of cruiseBORN ship has delivered performance that propeller blade tips and hull, if exceeded expectations propeller-induced noise was to be minimised. Six bladed 4.5m diameter hen Viking Star For the guest this means a few days fixed pitch monoblock propellers concluded its at sea, longer stays in ports and more were specified by shipbuilder sea trials in overnight stays in places of interest. Fincantieri due to hull vibration February, Captain In fact Viking Star’s maiden season modes. The number of blades Gulleik Svalastog was sold out before it was in the lowered pressure pulses, therefore declared it “one water, a key factor in the company the design challenge presented was ofW the most agile, state-of-the-art placing orders for ships two and to match the blade design to the hull and seaworthy ships on the water, three, which are scheduled to be to maximise propulsive efficiency, yet EFFICIENCY destined to exceed the expectations delivered next year. be exceptionally quiet. Close working of the most well-travelled guest”. Viking Star is 47,800gt and 228.2m Viking Star’s twin with the yard was key to the project. Promas systems have The cruise ship, built by long with a beam of 28.8m. It has 4.5m diameter fixed Using extensive hydrodynamic pitch propellers and leading Italian cruise ship builder nine decks and accommodates confer a high level experience, the rudders and Fincantieri is fitted with the its passengers in comfort in 465 of efficiency and propellers were designed, developed manoeuvrability. Rolls-Royce Promas integrated staterooms of different sizes, but all and analysed at the Rolls-Royce rudder and propulsion system, the with their own verandas. Hydrodynamic Research Centre in first time Promas has been installed In designing the new vessels, Sweden. Model testing, including on a new-build cruise vessel. Viking has incorporated a number cavitation and self-propulsion Viking Star is the first vessel to of the popular features from its tests, were undertaken by MARIN operate for Viking Oceans, the cruise successful river cruise longship in Wageningen, The Netherlands, arm of Viking Cruises which is the concept, which includes indoor and at the SVA cavitation tunnel at world’s leading operator with a fleet and outdoor dining venues, the Potsdam, Germany. of 53 vessels. Viking Star will host 930 Scandinavian preference for simple The tests confirmed very good guests on itineraries that start from airy spaces and variety – there are cavitation performance, a little the brand’s homeland in Scandinavia 15 different dining experiences to stable sheet cavitation on the and the Baltic through to the choose from. The top two decks are suction side and a very small tip Western and Eastern Mediterranean. a bespoke observation area, and a vortex. In fact, Promas improved Viking Oceans ordered three promenade deck allows guests to performance in all areas – speed, vessels, Viking Star and its sisters walk right around the ship. manoeuvrability and noise. Viking Sea and Viking Sky, from Equal attention has been paid to This improvement in efficiency is Fincantieri to bring in a new area of the ship’s systems. The hull designers achieved by several components. destination-focused ocean cruising. were well aware of the need for The twisted rudder shape adapts

32 design for these vessels, and as a result a majority of these vessels today with conventional CP or FP propellers incorporate Kamewa designs from Rolls-Royce in their propulsion systems,” says Robert Gustafsson, Senior Hydrodynamicist. “The design challenges are wide ranging and complex. They rarely mean just meeting class requirements, and can include ensuring the system can operate efficiently in several different modes, TRIED AND TESTED and in different water depths, all “THE VESSELS ARE DESIGNED Extensive model at the same time. Every vessel and testing of the application has its unique points, but Promas system was FOR DIRECT ACCESS TO MOST undertaken in The the experience used to arrive at the Netherlands and PORTS FOR EASY AND EFFICIENT Germany to perfect the best solution does not change. In design. fact it continues to grow with time. EMBARKATION AND DEBARKATION” “The focus for these innovative cruise vessels is not only on efficiency the rudder to the rotation of without increasing propeller-induced and noise, but also manoeuvrability, the propeller slipstream, giving noise and vibration. as they are designed for direct access lower drag and better recovery During sea trials, the ship’s to most ports for easy and efficient of swirl energy in the slipstream. contracted design speed of 20 knots embarkation and debarkation.” For slow speed manoeuvring, was achieved, with performance The Viking vessels are fitted with the cavitation-free steering angle above expectations in both energy-efficient engines and benefit range is also extended, enhancing propulsion and manoeuvrability. from a hydrodynamically optimised manoeuvrability. Getting propeller design right for and streamlined hull together with The rudder bulb reduces hub- any ship is very important, but in the Promas for maximum fuel efficiency. vortex losses and has a beneficial cruise and naval sectors it is vital. A number of systems combine to effect on the wake field. The hubcap It can have a direct impact on the minimise energy use onboard. As acts as a hydrodynamic fairing. A all-important guest experience and well as supplying the twin Promas different design of propeller blade potential survival for a naval vessel. system for the Viking Star, Rolls-Royce rebalances the loading pattern on “Rolls-Royce has over 40 years’ also integrated the steering gear and the various regions of the blade experience in perfecting propeller supplied the deck machinery. AR

33 CUSTOMER SUPPORT KEEP ON

EARNINGIn response to the need to reduce eeping drill rigs and downtime, Rolls-Royce now offers drill ships operating as planned and minimising a full turnkey support package for any downtime can have UUC azimuth thrusters to minimise a significant impact on operational disruption profitability. With the numberK of vessels equipped with UUC underwater mountable azimuth thrusters increasing over the last decade, Rolls-Royce has been listening to customer requirements and developed a turnkey support package that is flexible and can be tailored to individual needs. Periodic thruster maintenance is governed by prevailing class society focused on a single activity, drilling MATTI RANDELL rules. After five years in operation they for oil,” says Matti Randell, who heads must be visually inspected for wear. support for the Finnish built thrusters Thereafter this must be undertaken in Rauma. annually, until a stipulated full thruster “They have told us this is their overhaul is necessary. prime goal and they don’t want to be To get this work done, operators distracted by running teams normally allocate maintenance days in that manage maintenance and

“We understand their contracts, but with the growing overhaul tasks. that customer needs differ, therefore pressure on costs the number of days “We have therefore developed this the programme is being reduced all the time. turnkey programme to meet those is designed to be flexible.” “Most users of our UUC thrusters are needs, but it is flexible enough to be tailored to individual requirements, and for customers who may only require parts of the package.” The focus of the new programme is to ensure any thruster maintenance is completed in the shortest possible time, anywhere in the world, thereby reducing any time off-hire. Selecting different labour options allows customers to balance cost and time, which is enhanced when spare thrusters are available and enables an Digital immediate return to operations. To see a video interview with Matti Randell about the thruster Catering for support programme, download the different needs In-depth app from “We understand that customer needs iTunes or Googleplay differ, therefore the programme is designed to be flexible,” adds Randell. “Customers can select the

34 Support in full The UUC thruster turnkey support The programme has been developed to provide the best possible service, fixing overhaul costs and includes everything to ensure a successful thruster change-out in the shortest possible time. Rolls-Royce will take full responsibility for all aspects of the thruster exchange, working to an agreed timeframe. Repair and overhaul Thrusters are overhauled in one of four specialist Rolls-Royce workshops around the world, using genuine OEM spares at a fixed price*. The overhaul includes torque testing with full quality and inspection documentation for class requirements. (*Price varies by location and is dependent on key parts being reusable) Spare thrusters Supplied to the same specification as the installed units, with the parts of the programme that add the ABOVE: Mobilisation latest product improvements fully Integrating of crane barges or integrated. (Customers who own maximum value for them around the a heavy lift vessel, Condition together with the spare thrusters can maximise time overhaul activities.” transport of spare and cost savings) Monitoring units, can all be For example an operator with a The UUC azimuth thruster Condition included in a turnkey thruster support small number of rigs may find the cost Monitoring System (CMS) is package. Underwater of spare thrusters difficult to justify. classification society-approved with intervention Rolls-Royce offers the rapid overhaul ABS, Lloyds Register and DNV GL, and A dedicated project manager will coordinate all aspects of thruster of existing units, within 30 days (for can be fitted as part of the overhaul. removal and installation, including thrusters presenting normal wear Regular reports provide a level of the provision of service engineers, characteristics). detail for review during equipment divers, special tooling and crane Up to two thrusters can be surveys to determine the actual barge. On completion, class overhauled at the same time. With condition of the thrusters, without the documentation is provided. the underwater services included, need for expensive and often time- Logistics Rolls-Royce guarantees to remove, consuming internal visual inspections. Once a suitable service location overhaul and refit the thrusters within Maintenance and overhaul intervals and time has been agreed, all a set time. can be extended to anywhere transportation of exchange/spare between five and ten years. thrusters will be arranged, together with the necessary insurance. Fixing prices The system can be linked to the for no surprises onshore Rolls-Royce operations centre, Storage Four repair centres for UUC thrusters where the data is analysed by specially Long and short-term storage of have been established: Ulsteinvik, developed software to produce the spare thrusters at a pre-agreed Norway; Galveston, USA; Rio, Brazil; trending and operational information. location or service shop, plus regular and Las Palmas in The Canaries, It is then further analysed by technical upkeep maintenance at a fixed price ensures units are available for (opening Q3 2015). experts and regular reports are sent to immediate release. Thrusters that are part of the the owner or operator. programme can be overhauled at The availability of spare thrusters, Condition Monitoring these centres to a fixed price that together with detailed planning, is the All UUC thrusters, no matter their reflects the local labour rates. enabler for maximum time and cost age, can be retrofitted with the CMS during overhaul. New parts to take AR They are overhauled to OEM savings. the necessary sensors are fitted and standards and the latest product the unit returned with the necessary improvements fitted, and are supplied FIND OUT MORE interfaces for real-time reporting. with a full 12-month warranty. [email protected]

35 CUSTOMER SUPPORT

Plug & play A significant investment in the number of thrusters available across the most popular types now means full propulsion shipsets of FULL thrusters can be changed out in single dry docking. All aspects of the programme are tailored to individual requirements, to ensure shipowners SUPPORTTo help customers reduce vessel drydocking times, Rolls-Royce that use the Support Pool can has enlarged its Support Pool of azimuth and tunnel thrusters reduce the number of days a vessel would normally spend in drydock, to ensure quick replacement or a complete overhaul maximising the vessel’s revenue- earning potential. By using the thruster Support s a successful supplier or multiple tunnel bow thrusters for Pool the vessel owner can guarantee of one of the broadest manoeuvring assistance, with some availability of a replacement unit, ranges of thrusters in smaller vessels also equipped with which minimises downtime and the industry, a growing Azipull azimuth thrusters. avoids costly waiting time for parts number of vessels To help shipowners minimise and labour at the drydock. Even are equipped with drydocking times, Rolls-Royce with the best planning during a Aa full set of thrusters from the has enlarged its Support Pool conventional docking and overhaul Rolls-Royce family. with a number of additional routine, the right service parts can In the offshore sector, these thruster models. only be determined when a thruster may be azimuth thrusters for main That enables the exchange of is removed for overhaul. Missing or propulsion, with retractable and a complete ship set of azimuth incorrect parts can cause delays. tunnel units for manoeuvring and and tunnel thrusters, or just a dynamic positioning. Merchant single thruster as part of a planned Overhaul centres vessels may be equipped with single maintenance solution. Two European thruster overhaul

36 centres have been established, LEFT: Thrusters in the Support Pool are CASE STUDY in Gdynia, Poland and Ulsteinvik, stored at the repair centres in Norway Norway. Others are planned and Poland, while to provide global support. All other centres in Support Pool North America and will be equipped to similar Asia are planned. saves almost OEM standards, with full spin testing facilities. Thrusters in two weeks the pool will be overhauled and When the 2005-built platform stored at these locations. supply vessel Bourbon Topaz docked They can be shipped to wherever in the Ørskov Yard in Frederikshavn, the shipowner is docking the vessel, Denmark, in January for the overhaul so they are on the quay waiting for of its four thrusters, replacement the vessel to arrive, ready for a rapid units from the Rolls-Royce Thruster swap-out or to replace a damaged or Support Pool were already waiting. worn unit. The two main propulsion azimuth thrusters, 2,500kW Azipull Predictable pricing 120 units with CP propellers, the says Terje Fjelle of Bourbon Offshore The price for each thruster is based on swing-up TCNS 73 azimuth thruster Norway. fixed prices for overhaul labour and and the TT2200 tunnel thruster, The removed units were taken to the cost of a standard spare parts kit, were removed and exchanged the Rolls-Royce centre for overhaul plus on site service engineer costs. In with replacement units over an and testing, and then returned to the event of a thruster being found eight-day period. The vessel then the Support Pool. beyond the normal ‘wear & tear’ returned to operations. “We have a broad range of units condition, there is a capped price “A conventional well-planned in the Support Pool, so we can for additional spares that will not be multiple-thruster overhaul at the deliver similar time savings for other exceeded, so the potential worst case yard would take around 21 days, but shipowners at a fixed price, which cost is known from the start. using Support Pool units speeded helps with budget planning and “In developing the Thruster everything up and ensured there ensures minimal time in drydock,” Support Pool we listened to customer were no surprises or delays. It was says Geir Oscar Løseth, General concerns,” says Geir Sundal, Business also complete in the agreed time,” Sales Support Manager, Ulsteinvik. Manager Ulsteinvik. “They were primarily the thruster unit cost and the associated transport costs, which can have a significant impact on the overall price. Models in the Thruster Support Pool “We have therefore fixed the price of each replacement thruster and capped the cost of any overhaul, Tunnel Standard should anything unexpected be Swing-up Azipull thrusters Contaz modular found on stripdown. Having our (TV & TT) thruster support centres close to repair yards means customers can select repair yards that minimise the transport costs.”

Factory standards As some thrusters often serve 30 years or more they are still supported by Rolls-Royce, and when there are design improvements they are incorporated while the unit is being overhauled. TCNS 73, AZP 85 CP/FP, TV series: Contaz 15, US 205 The OEM 12-month warranty starts TCNS 92 AZP 100 CP/FP, TV90, TV150, Contaz 25 from when the thrusters are fitted AZP 120 CP/FP TV250, TV375 by Rolls-Royce engineers, not on TT series: delivery to the shipyard. AR TT1100, TT1300, TT1650, TT1850, FIND OUT MORE TT2000, TT2200, thrustersupportpool TT2400, TT2650 @rolls-royce.com

37 CUSTOMER SUPPORT To the

A dedicated Rolls-Royce facility to test the gas turbines on the Royal Navy’s Type 45 fleetMAX will support the destroyers’ demanding schedules

olls-Royce has opened efficiency objectives, Rolls-Royce TESTING As the new WR-21 cell replicates a new facility to used its existing marine gas turbine the engine installation in the Type 45, support the service test infrastructure, adapting and it will also be used to evaluate and and testing modifying the MT30 test cell in assess changes in engine operation requirements for the Bristol. Systems and components and service improvements long before Royal Navy’s next from the MOD’s decommissioned they go to sea. The cell has high generationR of destroyers. land-based Electric Ship Technology potential for use as a complementary Vice Admiral Simon Lister, Chief of Demonstrator were reconditioned training aid for Royal Navy personnel Materiel (Fleet), Defence Equipment and incorporated into the new cell. MT30 and WR-21 alongside existing facilities. marine gas turbines and Support (DE&S), unveiled a The facility now includes separate can now be tested The Type 45 is the world’s first in the same facility, commemorative plaque to mark the but adjoining cells that can test MT30 simplifying logistics. major surface warship to adopt centre’s opening at Filton, Bristol, UK. and WR-21 marine gas turbines. This integrated electric propulsion where The Rolls-Royce Marine Test facility will deliver operational efficiencies, two Rolls-Royce WR-21 gas turbines includes a new WR-21 test cell to not only for Type 45 support, but drive 21MWe alternators combined support the in-service requirements also for the future Royal Navy fleet with two 2MWe diesel generators of the Royal Navy’s Type 45 destroyers. that will be powered by MT30, the sets to supply power to the ships’ It can service and test both WR-21 world’s most power dense marine propulsion motors and services. and MT30 marine gas turbines and gas turbine. This additional capability Rolls-Royce has a range of is equipped with load cells to test means that the gas turbines installed other equipment installed on engines delivering up to 40MW. in current and future class vessels can the class – LV electrical systems, Vice Admiral Lister said: “The Type all be split into modules for overhaul, propellers, shaftlines, bearings, 45 destroyer is truly a breakthrough rebuilt and tested at one centre in stabilisers, steering gear, anchor vessel, and the most advanced the UK, for simplified logistics. and mooring windlasses. AR warship ever to be deployed by the Royal Navy. Key to its future success is the performance of the WR-21 gas turbine. Having a dedicated facility that can service and test these unique engines to maximise availability is essential if we are to ensure the Type 45 is constantly operationally effective.” Don Roussinos, President – Naval said: “This unique facility not only demonstrates our capabilities in support of the Type 45 programme, but also the close working relationship Rolls-Royce has with Digital To see a video of the Royal Navy. A key part of the the new test bed relationship was to build an overhaul in our digital edition, download and test capability to maximise the the In-depth app from iTunes or availability of the WR-21 engines to Googleplay support the destroyers’ demanding operational schedules.” To meet Ministry of Defence

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