Issue 33 ● September 2018
Legend in the making
After the successful launch by its namesake, we reveal how RRS Sir David Attenborough will change polar research
Pages 30-33 12-15 22-23 42-45 A revolution in propulsion Perfect balance Strength to strength New compact ice-class Elegance How retractable stabilisers provide As 10,000th Kamewa waterjet is pods offer a graceful approach safe passage for ice-going ships delivered, we salute versatile hero
Contents
ISSUE 33 ● SEPTEMBER 2018
Opinion
10 Kevin Daffey Our Director, Engineering & Technology
Innovation
12 Elegant solution 20 Secret tests result in a new range of compact ice-class pods
16 The best of both worlds Propulsion “We'll reach the most attractive Innovation continues with new portfolio by year end and multipurpose hybrid vessel 34 Cruise control Hurtigruten's new expedition continue to grow within the 18 The journey to Zero Waste cruise ships will feature one high-speed segment” Oskar Levander discusses the of the world's most efficient advances in marine efficiency propeller systems: Azipull-L Services Products Naval 42 46 The ship's doctor 20 Winds of change 36 Powering though a decade We explain how our new Innovative new Boat Transfer Why the MT30 marine gas Special Health Management system System allows daughter craft to turbine has been on top Feature harnesses the power of data be deployed simply and safely for 10 years Still going strong to give an holistic overview The 10,000th 22 A perfect balance Ship Intelligence Kamewa waterjet With its distinctive swept fin, has entered our retractable stabiliser offers 40 All hands on deck service – so we steady ice-going navigation New team of former captains look back at brings wealth of experience to its remarkable 24 Pulling power the autonomous ship concept history More flexible tug operations are on the horizon thanks to the new lightweight PM electrical motor Customers 48 26 Dreams become reality How the Uzmar shipyard in Turkey became the fastest builder of state-of-the-art tugs 48 Canaries flying high The Rolls-Royce Service 30 New depth of knowledge 26 workshop in Las Palmas is We go behind the scenes to find flourishing again as offshore out more about the incredible Exploration & Production RRS Sir David Attenborough continues its recovery
© Rolls-Royce plc 2018. The information in this publication is the property of People Bill Thomson and Patrik Wheater Rolls-Royce plc and may not be copied, communicated to a third party, or used for any purpose other than that for which it is supplied, without the express written Editor: Craig Taylor Production: Connect Publications Ltd consent of Rolls-Royce plc. While the information is given in good faith, based upon the latest information available to Rolls-Royce plc, no warranty or representation Deputy Editor: Nigel Allen Cover image: The newly-launched is given concerning such information, which must not be taken as establishing any Design: Ryan Swinney RRS Sir David Attenborough and contractual or other commitment binding upon Rolls-Royce plc or any of its subsidiary or associated companies. Opinions expressed may not necessarily represent the views Contributors: Craig Taylor, Richard its famous TV naturalist namesake. of Rolls-Royce or the editorial team. The publishers cannot accept liability for errors or omissions. All photographs © Rolls-Royce plc unless otherwise stated. White, Anette Bonnevie Wollebæk, Image: Cammell Laird.
Rolls-Royce Indepth magazine 03 UPFRONT
Thought leadership from Mikael Mäkinen, President – Marine A WORLD OF NEW HORIZONS
his issue of Indepth will be available at SMM Hamburg, where a vast array of “Our customers can now have technology will be on display and no access to real-time information doubt the discussions will again focus on digital technologies. about the health of their The development of new technology onboard equipment and systems” often grabs the headlines and I’m sure this SMM will be the same. For the customers I talk to, cost Tand the value they will get over many years’ service is what really matters, so we’ve focused on developing products that we strongly believe will add value over the longer term. Our latest propulsion offering is also a significant We’re launching our latest Health Management step for us. We’ve seen a gap in the market for podded (HM) offering – a pioneering solution that promises to propulsion up to 7MW. We then looked at operational data revolutionise the way our customers manage their assets. from our larger in-service pods, and with electrification Through the smart analysis of data and the lessons we gathering pace across the industry, considered the right learn from machine analysis, our customers can now have solution for the future. access to real-time information about the health of their Drawing on our experience with Permanent Magnet onboard equipment and systems. This isn’t only restricted (PM) technology, we’ve returned to the pod market with an to Rolls-Royce equipment, as the HM system can also offer all-new PM powered compact pod and that means we now insights into third-party equipment. have the complete electric propulsion range, offering that To control costs effectively, there must be ship- all-important choice to our customers. wide scrutiny to identify where operating costs can be This time we’re offering more than the pod alone. minimised. This stretches from the bridge to below the In a new approach, we feel the pod offers even greater waterline and beyond when fleet-wide performance efficiency when combined with an electrical system that READ MORE is considered. can be adapted to fit a variety of vessels, and also can We’ve put a lot of focus into continually driving for include batteries. efficiency improvements in our product development, The system, which we’re calling Elegance, balances 46 but we also appreciate our customers have their own system performance and efficiency with unique preferences and therefore believe choice is a key part hydrodynamic advantages, thanks to its sleek, slimline –47 of what we offer our customers. shape. You can read more on page 12.
04 Rolls-Royce Indepth magazine “The maritime industry is at the dawn of a new and exciting era where digital and electrical technologies will transform shipping”
READ MORE 12 –15
The new Elegance propulsion system will see graceful innovation in action
The question of cost is also key when it comes to The move follows a strategic review by Rolls-Royce existing assets. We’re beginning to see an increase in of its Commercial Marine operations that we announced reactivation of vessels and rigs, and cost is front of mind in January. for our customers. Being able to offer cost effective This marks the start of a new horizon for our products and service is something we strive to do, and Commercial Marine business and comes at a time we’ve been able to provide attractive ways of getting when the maritime industry is at the dawn of a new and vessels back in service. exciting era where digital and electrical technologies Our partnership with Astican shipyard in the Canaries is will transform shipping. really taking off, and with a significant increase in demand We expect the deal to conclude early next year and for thruster overhauls, we’ve changed our approach to remain fully focused on ensuring a smooth transition for better suit our customers’ needs. This close collaboration all our customers, throughout this period. means we can offer a fixed price for both docking and Rolls-Royce has been responsible for leading many overhaul, something which takes away a lot of hassle but technological advancements and with a combination of The new Health maintains the high-quality service. great people, market-leading technology and a desire Management system reports In other news, no doubt you will have seen the by KONGSBERG to take this business to the next level, on the wellbeing announcement in July, regarding the decision to sell the I am sure that this business will prosper in the years of equipment Rolls-Royce Commercial Marine business to KONGSBERG. to come. ●
www.rolls-royce.com/marine [email protected] www.linkedin.com/company/rolls-royce
Rolls-Royce Indepth magazine 05 NEWS
The latest developments from the News wider world of Rolls-Royce Marine Rolls-Royce agrees to sale of Marine business to KONGSBERG
Norwegian group will take control of commercial Commercial Marine business. It arm after Rolls-Royce signs historic agreement comes at a time when the maritime industry is at the dawn of a new KONGSBERG, headquartered to enable remote and autonomous and exciting era where digital in Kongsberg, Norway, is an operation of commercial vessels, and electrical technologies will international, knowledge-based are also included. transform shipping. group delivering high technology KONGSBERG will, through “Rolls-Royce has been systems and solutions to clients a trading arrangement, continue responsible for leading many of within the oil and gas industry, to have access to products from those technological advancements, merchant marine, defence and Bergen Engines, which remains and with a combination of great aerospace sectors. part of Rolls-Royce. people, market-leading technology The move follows a strategic The Bergen engine range of and a desire by KONGSBERG to review by Rolls-Royce of its both diesel and gas medium- take this business to the next level, Commercial Marine operations speed engines is a key component I am sure that this business will announced in January. The that will enable KONGSBERG prosper in the years to come." sale includes propulsion, deck to be a leader in the continued machinery, automation and control, development of integrated a service network spanning more ship systems. “This agreement than 30 countries and ship design KONGSBERG will also be an marks the start of capability, which to date has seen important partner and supplier to around 1,000 ships of Rolls-Royce Rolls-Royce’s Defence business for a new horizon for design delivered to offshore, the supply of Commercial Marine cargo, passenger and fishing vessel products used on Naval vessels. our Commercial customers worldwide. Mikael Mäkinen, Rolls-Royce Marine business” Rolls-Royce’s Ship Intelligence President, Commercial Marine, activities, which have seen the added: “This agreement marks rapid development of technologies the start of a new horizon for our Mikael Mäkinen
06 Rolls-Royce Indepth magazine Arctic Storm thinks big Rolls-Royce Marine has signed a contract with Thoma-Sea Marine Constructors LLC in Louisiana, USA, for the development of a state-of-the- art pelagic trawler. The vessel is to be built for the Seattle-based company Arctic Storm Management Group LLC. In addition to being Rolls-Royce's largest fishing vessel contract, valued at about £15 million, it also marks the first Rolls-Royce fishing vessel concept to be built at a US shipyard. Rolls-Royce has been working closely with Arctic Storm to develop this latest design. The vessel will be equipped with a processing plant for The Rolls-Royce NVC 336 WP generator sets. This arrangement The NVC 336 WP fillet, surimi, fishmeal and fish oil. It will design is scheduled for delivery in is designed to optimise and meet is 100m long, with also be able to accommodate a crew 2021, and it will be 100 metres long, the requirements for low fuel a 21m beam of more than 150 people. with a beam of 21 metres. It is arranged consumption, reduced emissions Doug Christensen, CEO of Arctic for pelagic trawling in the North and low noise and vibration levels. Storm Management Group, said: “This Pacific, catching pollock and cod. will be the largest and most advanced In addition to the design, fishing vessel ever built in the USA. Rolls-Royce will deliver an “This will be the largest and "The fact that both the design integrated package of advanced most advanced fishing vessel and the supply and integration of the ship technology and equipment to comprehensive equipment package the vessel. The propulsion system is ever to be built in the USA” is provided from, and coordinated by, based around a Bergen B33:45 main Rolls-Royce is a key enabler for us.” engine in combination with Bergen Doug Christensen
Turning night into day – a screen shot from the trial
Success for Intelligent Awareness trial with MOL
The capacity for Intelligent Awareness Rolls-Royce installed an array of (IA) and machine learning technologies to IA sensors, thermal imaging cameras significantly improve navigational safety and its revolutionary Light Detection has been verified by Rolls-Royce and and Ranging (LIDAR) system on the Japanese shipowner Mitsui OSK Lines vessel in March 2018, following the (MOL), following the success of a pilot 2017 signing of a joint development project aboard a 165-metre passenger ferry. agreement with MOL. Results from sea trials on the Sunflower The technology was fused together – which operates night-time sailings The ferry to give the vessel’s bridge team day- between Kobe and Oita in Japan – found Sunflower time-like situational awareness of the that the vessel’s navigating officers were surrounding area, providing enhanced able to visually detect objects that would decision-making capability and otherwise have been cloaked by the “During the trials, the IA system was able to improving the safety of the vessel. blackness of night. detect all potential navigational obstacles, “We turned night into day,” said Iiro Lindborg, General Manager, Remote allowing the crew to mitigate against any Lindborg. “MOL and the Sunflower crew & Autonomous Solutions, Rolls-Royce, said: safety risks during night crossings.” were very satisfied with the results.”
Rolls-Royce Indepth magazine 07 NEWS
Green power for Norway’s
Rolls-Royce has signed new deal with Finferries coastal routes With the Norwegian southwest to Kirkenes, a key SVAN launched to optimise government recently requirement of the renewal ship safety and efficiency awarding 11 new licenses for was for operators to reduce the renowned passenger and CO2 emissions. cargo route from Bergen in the For the first time, the Rolls-Royce and in the AAWA project Finnish shipowner is to continue. This Finferries have signed new collaboration a collaboration agreement could take agreement to jointly safer, cleaner shipping develop strategies and to the next level. solutions to optimise the “Rolls-Royce will safety and efficiency develop solutions to of marine operations enhance the safety and through developing the efficiency of marine technology for decision operations in the ferry supporting systems and sector, which will be to demonstrate remote demonstrated in the and autonomous ferry test platform provided operations. by Finferries.” A key focus of the Mats Rosin, collaboration will be to Finferries CEO, added: consider a new research “We are excited to project, called Safer further deepen our Vessel with Autonomous collaboration with Navigation (SVAN), Rolls-Royce. whereby Rolls-Royce "Finferries wants and Finferries will to actively take part in look to implement ventures where cutting- the findings from the edge technology is Advanced Autonomous utilised to increase The vessel houses Waterborne Applications the safety in maritime turbine technicians (AAWA) research project, operations. which formally ended in “We believe this late 2017. cooperation will Karno Tenovuo, benefit both our Senior Vice President, customers and the Rolls-Royce Ship environment Intelligence, said: by focusing “We are extremely on raising pleased that the marine collaboration we traffic had with Finferries reliability.” svan
08 Rolls-Royce Indepth magazine licenses have been split between CO2 emissions by at least Colleagues two operators, Hurtigruten and 25 per cent. new entrant, Havila. The intentional agreement pay tribute to Hurtigruten has selected specifies that Rolls-Royce is writer Richard Rolls-Royce technology, to to deliver two of its Bergen meet the strict environmental B36:45 L&PG gas engines Richard White, regular demands of the new operating as the main engines to each contributor to Indepth since licenses. It will carry out a ship. These LNG engines set the very first issue in 2000, major upgrade of six existing a new standard in power and has died aged 73. passenger cruise ferries, with efficiency with exceptionally His combination of options for a further three. The low emissions of NOx, SOx, CO2 technical knowledge, seafaring upgrade will involve installation and particulates. Rolls-Royce experience and an enquiring of Bergen LNG engines as part will also supply the latest mind made Richard one of the of a new hybrid system. The electrical power SAVe Cube best communicators of marine upgrade combining LNG and system, designed with a single engineering. batteries will enable the former integrated drive switchboard for As well as a career at sea diesel-powered ships to reduce the whole vessel. and in boatyard management, Richard held senior editorial positions at several leading Read more maritime technical magazines, news and updates on the including The Motorship, free Indepth mobile app Marine Propulsion and Offshore Support Journal. Indepth for iPhone is on the Apple Fluent in Norwegian, App Store and on Richard’s journalism skills Google Play for Android devices were also welcomed by Ulstein Group, Vickers and subsequently, Rolls-Royce where he would play a leading role in developing Indepth and numerous technical publications for the growing product range. Head of Communications Craig Taylor said: “Richard will be sorely missed by his many, many friends in Rolls-Royce technology will be at Rolls-Royce Marine and his the heart of the Hurtigruten vessels technical writing capability will be hard to replace.” First SOV starts work The first of two Rolls-Royce Spain, the vessel is working on design UT 540 service operation DONG Energy’s Race Bank wind vessels, has set to work in the farm 27km from the coast. North Sea. Technicians walk to work Boat transfer Operating a two-weekly cycle across a specially designed system: Pages from Grimsby, UK, the Edda Passat motion compensated serves as a base for wind turbine gangway that is hydraulically 20-21 technicians while they carry out raised or lowered on a essential maintenance. pedestal. This gives the workers Richard White contributed to Ordered by Østensjø Rederi safe and level access to the the pages of Indepth for 18 years in 2015, and built by Gondan in turbines at different tides.
Rolls-Royce Indepth magazine 09 OPINION
The way forward
“I do see a future where certain ship types will become completely unmanned”
10 Rolls-Royce Indepth magazine ur autonomous ship journey really Kevin Daffey, Rolls-Royce Director Engineering started in 2014 with & Technology and Ship Intelligence, offers further the unveiling of our futuristic oX Bridge insight into an autonomous shipping future concept, although you could say it goes as far I would not like to suggest that every us that a system or machine is working as back as the mid-2000s, when we introduced ship will be unmanned and autonomous, it should. Anything outside normal running Oour first Dynamic Positioning system and, but I do see a future where certain parameters immediately shows up. later, the ACON automation system. This ship types will become completely What we are trying to do is create an was when we started including automation unmanned. Initially, there would be a broad engineering system onboard a vessel that technologies into our offshore portfolio; it progression, with more levels of automation is survivable for a complete voyage. You provided a kernel for the development of being introduced to transfer some of may have some maintenance interventions advanced positioning and control systems. the tasks from ship to shore-based ship onboard by robot arms, but when the We also saw what was happening in operation centres. vessel is alongside, that’s when any repairs the aerospace sector with engine health For example, instead of every ship and maintenance will be carried out. monitoring and felt we could adapt the having a finely trained chief engineer We are learning a lot from other concept and apply it to our engines and onboard who has 20 years of experience, industries. The automotive sector is many propulsion systems to play an important why don’t we tap into this experience years ahead of us as far as autonomous part in the maritime industry, especially in and bring them shoreside, providing vehicles are concerned. The rail industry is terms of operational performance, safety expertise and guidance to less well-trained also beginning to move across to autonomy. and maintenance. This is now at the core of equipment maintainers onboard, who would Our latest agreement is with the European our Marine ‘Power by the Hour’ contracts. carry out any necessary interventions? Space Agency where we hope to learn how Rolls-Royce has been at the vanguard Remote operation would still require the you design, build and operate a remotely of development in this area, producing same knowledge and experience seafarers controlled space vehicle for years without systems capable of capturing data and have and they will still need to use all the physical human intervention. And forward- accurately monitoring the health of senses – sight, sound, smell, touch – which thinking shipowners and operators will equipment, particularly our Bergen was something we became aware of during begin to see the competitive advantage in engines, thrusters and deck machinery, the testing of the world’s first remote- employing autonomous technology. where we now have a very mature data controlled tug, Svitzer Hermod. I really do think we’re going to see pattern. This is critical to the development During trials, we found that when the an acceleration of interest. Technology of the autonomous ship so we can ensure vessel’s thrusters engaged, the remotely companies are beginning to see the The way forward
highly reliable systems that don’t require located master had to wait for the tug’s maritime sector as providing a new outlet ‘at sea’ interventions. And while the motion to be seen on the video wall to for their technologies. Our industry is quite concept is very much at the embryonic confirm the thrust was manoeuvring the fragmented. But in other industries, such as stage, the technology is there, especially tug. On ship, of course, you’d be able to telecoms, IT and automotive, there is much now that the communications industry has hear the thrusters, feel the vibrations. more trans-industry integration, and this is developed the broadband capacity This gives the Captain immediate feedback a business model that will eventually filter required to send, at a cost-effective rate, that his actions were going to cause an across to the maritime industry. high volumes of data from ship to shore or effect. So, to ensure shore-based operators You can see this happening now shore to ship. still have that sensory understanding, with cooperation agreements between Certainly, in the last five years, we introduced a speaker into the remote companies like Maersk and Ali Baba; development in sensor technology and control centre and created a deck Rolls-Royce and Google. There will satellite communications has advanced that vibrates. certainly be a bigger push from the to such an extent that we now have that Today, ship maintenance is typically owners of the goods and commodities capability. Although we manage data diagnostics, but the level of sensors and looking to integrate the whole logistics transfer rates in a cost-effective way. For data we have available allows us to be more chain to include greater aspects of instance, during long ocean passages, high prognostic, to see a problem beginning maritime operations. ● bandwidth video feeds are not required. to take shape and act upon it before it However, in and around ports, it’s easy now manifests itself. What I envisage is greater to set up a wireless or 4G connection, so we use of machine learning technology, a can traffic vast amounts of data captured branch of Artificial Intelligence, where we For more information, email from a voyage and harvest those insights. can use self-adapting algorithms to show [email protected]
Rolls-Royce Indepth magazine 11 INNOVATION
By Patrik Wheater
Following a top-secret series of trials and testing, Rolls-Royce’s new Elegance range of compact ice-class pods brings a truly graceful approach to propulsion ELEGANT SOLUTION UNVEILED
olls-Royce has emerged compact ice-class pods for the 1.5MW from a closely guarded to 7MW power range. four-year research and The Elegance pods – one with development project an open propeller, the other ducted with a completely new – complement and complete our podded propulsion existing portfolio of mechanical and system, designed to meet a customer electric propulsion systems. They Rdemand for additional competition in are being marketed towards the the electric propulsion segment. cruise and passenger ferry segments, Having evaluated the operational and expedition-type vessels in data from the 50 Rolls-Royce particular. But they are also suited Mermaid units currently in service, to other applications like rigs, tugs followed by extensive computational and workboats. fluid dynamics (CFD) and testing at Per Nahnfeldt, General Manager our hydrodynamic research facility Product – Electric Propulsion, in Kristinehamn, Sweden, we have Rolls-Royce, explains the thinking been able to develop a new series of behind the development. “For
12 Rolls-Royce Indepth magazine many years we have seen a gap in the podded propulsion market for smaller units up to 7MW – a power output that is significantly less than the Rolls-Royce Mermaid system and more comparable with conventional thruster ranges. The market has, however, been content with the mechanical thrusters we have been providing. Now, with an electrification process taking place across the marine industry, we found the time was right to move ahead. “We started developing the concept in 2014, taking performance statistics from the Mermaids and analysing an enormous amount of real-time condition monitoring data to design a reliable, an extensive system optimisation ABOVE, BELOW electric systems are designed hydrodynamically-efficient pod, approach, this has resulted in a AND FAR LEFT: to fit a various range of vessels, knowing the podded propulsion is pod that optimises the trade-off The ducted giving an enhanced diesel-electric proven to be very efficient. These between electrical, mechanical and propeller performance that are optimised for version of new pods complement our broad hydrodynamic efficiency, utilising each shipowner’s use. the new product portfolio and sit well with our expertise within all these fields. Batteries can be integrated in Elegance pod our range of frequency drives. “The PM technology and the the SAVe systems to perform load We can now provide a complete motor fitting in the casing, inherited smoothing on the engines and electric propulsion package.” from the Mermaid range, allowed us increases the redundancy of the Both pod types build on the to create a sleek, slimline pod, which vessel. The SAVe system can then experience gained from the adds significantly to hydrodynamic deliver continuous power to the Mermaid’s more than 4,000,000 efficiency.” pods, allowing a power-generating operational hours and data from our The pods capacity reduction by up to 30 range of market-leading mechanical are delivered in thruster products and refined to a system with incorporate the latest in permanent Rolls-Royce magnet (PM) motor technology. Active Front This consists of two main parts End Converters, – a stator that carries a number of either fed from electrical coil windings, and a rotor a conventional fitted with permanent magnets. 690V system A rotating magnetic field is created or through by the stator which interacts with the transformers on a fields of the permanent magnets on medium voltage the rotor, which generates force to distribution drag the rotor around, providing the system, such mechanical power. as our SAVe “The use of PMs provides a Step solution. high motor efficiency over all The different speed ranges," says Per. "Based on Rolls-Royce SAVe
Rolls-Royce Indepth magazine 13 INNOVATION
per cent. This means the pods could operate on battery power alone when in harbour, or for limited periods with zero emissions, dependent on the battery capacity. “The combination of the permanent magnet motor in the pod and battery adds valuable benefits to the vessel operation,” says Sigurd Øvrebø General Manager for Electric and Power, Rolls-Royce. “The efficiency at part load is “The efficiency at part so high that we can potentially add 25 per cent operation time at low load is so high that we can load conditions in ports and fjords, compared to an induction motor- potentially add 25 per cent operation based system. The new Elegance time at low load conditions” system, when including batteries, offers zero emission operation as one Sigurd Øvrebø of the new popular and important operation modes.” Through a complete system into a vessel,” adds Hans Martin improving hull efficiency. This also package, Rolls-Royce performs the Hjørungnes, General Manager allows the height and tilt of the pod system integration between all their Product Systems, Rolls-Royce. to be adjusted, allowing operators products to ensure that the newly- The high hydrodynamic to select the optimum propeller size released pod, the electrical system, efficiency of these new pods, for the vessel. the engines and the automation however, cannot be underplayed, The pods have also been designed system work together as one given the detailed research, CFD to meet 1A Super and Polar Code 6 complete vessel system. analysis and model testing that has ice-class requirements for operations On top of these components, gone into the design. in the Baltic and Arctic sea areas. Rolls-Royce can supply and integrate For instance, the pods feature A key design philosophy that digital solutions such as Energy a ‘twin tail’ concept to improve Rolls-Royce has been successful Management, Autocrossing and the efficiency and significantly reduce in incorporating into the pods award-winning Unified Bridge. cavitation-induced noise and is installation and maintenance “System integration is about vibration, while a new integrated simplicity. For example, should the adding value through optimising hull fitting interface allows a pods need to be replaced they can the performance and reliability of compact head-box to be used, be lifted and mounted in water. all products and systems that go minimising drag and further This builds on the experience
How the new Elegance pod system will work
14 Rolls-Royce Indepth magazine from the underwater mounting of advanced leaps and bounds in the Rolls-Royce azimuthing propulsors last 15 years.” According to Per, the and provides a means for bearings have a life expectancy of replacement of the complete units, ten years or more before they need including the steering gear, for ease replacing. The same overhaul period of maintenance and service in – as applies to the inboard and outboard well as out of – drydock. seals and slip rings. Carrying on the maintenance “The reduced maintenance theme, there is no need to enter the requirement correlates to a low life- pod as all those components that cycle cost,” he says. “The lubricating do require servicing are in the unit’s oil requirement for these high steering unit area. efficiency, low energy pods, has also Both pushing and pulling pods been reduced. There are no oil-to-sea have been designed with several interfaces and should system oil leak layers of redundancy on critical at all, it is fed into a dedicated sump and hard-to-reach components, connected to the ship’s bilge system.” with service points positioned for Having officially unveiled the ABOVE AND Read more about easy access. Elegance range in Hamburg, at the our propulsion RIGHT: The systems on the Maintenance is further optimised SMM 2018 trade show, Rolls-Royce open propeller free Indepth mobile app. by way of fewer moving parts within is now building a 4.6MW unit at its version of the the below-the-waterline housing. In Rauma facility and is in discussions Elegance pod Indepth for iPhone is on the Apple App the main, the only components that with shipowners to install the pod in Store and on Google require drydock service are the a pilot project. Play for Android devices pods’ bearings and seals. “We have worked tirelessly to Acknowledging the bearing develop a pod that balances system problems that have beset all pod performance and efficiency with manufacturers at one time or another unique hydrodynamic advantages. some years back, Per explains that We have achieved material breakdown occurred only that objective with when scaling up the bearings for Elegance,” Per says. ● pods with power outputs of 14-15MW or more. To find out “The bearings in the smaller units more, email were fine,” he says. “What’s more, per.nahnfeldt@ bearing and seal technology has rolls-royce.com
“These new pods complement our broad product portfolio and sit well with our range of frequency drives. We can now provide a complete electric propulsion package.”
Per Nahnfeldt
Rolls-Royce Indepth magazine 15 SUSTAINABILITY
High efficiency and low emissions are the By order of the day as the latest craft for Norway’s Richard Coastal Administration demonstrate our ongoing White innovation in multipurpose hybrid vessels
Caption caption caption caption RYVINGEN IN ACTION
6 main engine cylinders
2 PM azimuth thrusters The best 2 independent of both worlds batteries s Norway’s for improved levels of crew safety, systems and equipment. In its first Coastal lower operational cost and a smaller full year of operation, the vessel Administration environmental footprint. sailed 10,000 nautical miles and (NCA, Rolls-Royce Marine worked showed a significant reduction 1 Kystverket) with NCA on power, propulsion, in fuel consumption compared single medium continues its dynamic positioning (DP) and with the first pair. speed engine fleet renewal systems integration for the programme, hybrid propulsion first two new vessels, designed Ais the key to efficient and low by Heimli and built by Fitjar emissions operation. Mekaniske Verksted in 2011-12. NCA vessels are responsible Four high-speed diesel generators for maintaining lighthouses and supplied propulsion motors on navigation marks along Norway’s twin shaftlines via multidrive units, extensive coastline. They also have which also supplied power to the oil spill clean-up and emission bow and stern tunnel thrusters. control duties, making for a very Positive experience with these varied operational profile. ships gave NCA confidence to go When the time came to replace further in the quest for operating the 20-30 year old vessels, NCA set efficiency by using hybrid about realising its vision of making propulsion technology. Designed the coastal waters the safest and and built in Denmark, the third A single medium-speed Bergen engine cleanest in the world. The vessels vessel, OV Bøkfjord, went into has replaced the six high-speed diesels themselves have been designed service in 2016 with Rolls-Royce
16 Rolls-Royce Indepth magazine six. The row of high speed diesels has been replaced with a single medium-speed engine; a Bergen 25:33L6AV rated at 2,000kW in BELOW: The a configuration with a permanently OV Ryvingen connected generator driven from each end of the crankshaft. Each generator feeds one side of the switchboard. In combination with the two independent batteries, this arrangement gives the desired electrical redundancy. Power is then distributed to the two permanent magnet (PM) azimuth thrusters, type PMAZM 1900, each taking 1,100kW, the 400kW tunnel bow thruster, and the hotel loads. These azimuth thrusters with the PM motor in the nozzle have demonstrated their high efficiency under a wide range of operating conditions. Since OV Ryvingen will spend a proportion of its time in port, either Operating profile breakdown manned or unmanned, two 99kVA shore connections will be installed to allow the engine to be shut down, while batteries are topped OV Bøkfjord was one of the harbour. To allow the parameters for up and other loads covered from first vessels to have a large-scale the integrated hybrid system to be the Norwegian grid, which is largely energy storage system, in set correctly, a much more detailed based on renewable resources. the form of an 800 kWh analysis was made. This is shown in In addition to power and battery. Electrically powered the above diagram and includes data propulsion, Rolls-Royce is also azimuth thrusters replaced from the operation of OV Bøkfjord providing systems for NCA’s new shaftlines, removing the as logged by the Integrated Energy vessel that are important for its need for an aft tunnel Management (EM) system. efficient operation. thruster. The battery “The analysis gives us and NCA These include Remote Access, replaced one of the a much more precise picture of Energy Management 2, power diesel gensets. what is required of the power and management, integrated blackout propulsion system to enable the new prevention system (BPS), ACON vessel to perform its wide ranging integrated automation, Helicon X3 “OV Ryvingen’s 3MWh of duties with the minimum of energy control, Poscon joystick and ICON energy storage is probably consumption and emissions,” says dynamic positioning to DP1 class. Bjørn-Erik Osmark, Rolls-Royce “Economy modes can be used the largest installed to date Marine Digital & Systems. during several types of operation” in a vessel of this size range” “It has led us to a radically says Kristian Eikeland Holmefjord, different solution centred on Rolls-Royce, Digital & Systems. the SAVeCube integrated DC “When working at sea there are Bjørn-Erik Osmark switchboard with a single medium- periods when the full positioning speed diesel engine, two batteries accuracy of the DP1 system is not Now, the technological and PM azimuth thrusters. needed, so a relaxed DP mode can developments of these vessels “SAVeCube houses the DC bus, be selected which allows a larger are being taken a big step further all drives and frequency converters degree of drift-off, reducing thruster with OV Ryvingen, currently under in a single cabinet. use and saving energy. construction at Fitjar for delivery "It allows the two 1,500kWh “In harbour, the two shore power towards the end of this year. batteries to be simply connected systems with a connection on each Compared with the first three it to the DC system and the engine to side of the vessel can take any is slightly longer and has a larger run at variable speeds to optimise voltage and frequency available. crane capacity. The major advance its efficiency. OVRyvingen’s 3MWh "OV Ryvingen will spend periods is in the Rolls-Royce Marine hybrid of energy storage is probably the tied up in harbour, either manned or propulsion system. largest installed to date in a vessel unmanned, and an eco mode allows A broad breakdown of the of this size range.“ all non-essential electrical loads to operating profile for the NCA A major difference between the be shut down, leaving only those vessels showed that 28 per cent of new vessel and its predecessors required to keep the vessel safe, the time is spent in DP mode, 20 per is that the number of main engine ready and habitable, cutting energy cent in transit and 52 per cent in cylinders has been cut from 42 to consumption to the minimum.” ●
Rolls-Royce Indepth magazine 17 SUSTAINABILITY
Oskar Levander, SVP Concepts & Innovation, Rolls-Royce Marine, explains why new intelligent technology will help the marine industry make a quantum leap towards improved efficiency and less waste THE JOURNEY TO ZERO WASTE here are two main that upcoming regulations will focus When looking at reducing waste, trends in shipping more on greenhouse gas and particle thoughts quickly go to improvements – digitalisation and emissions. Indeed, the International in the Japanese car industry. They environmental focus – Maritime Organisation has declared define that every activity conducted
that are driving most of the target to reduce CO2 emissions is either value add or non-value the development in the by 50 per cent before 2050. add. This Japanese lean leadership marine industry. Current environmental regulations culture has defined seven types of TDigitalisation will be disruptive are usually tackled by installing waste in processes, referred to and change all parts of the industry, exhaust and water cleaning as MUDA. from the way the ships are operated equipment onboard or by selecting As you'll see on these pages, I’ve and managed, and how they look compliant fuels. taken the liberty of slightly modifying and function, to totally new business I believe we need to approach the the process waste list to be more models. The digital development will environmental challenge differently relevant for ships and also also become one of the means to going forward and not only reduce made a definition of seven meet environmental goals. emissions on ship level. We need to types of waste in shipping. The marine industry is today look at how the resources are used For example, transport is focusing on how to comply with and how efficiently we operate the removed, as transporting the NOx, sulphur and ballast water world fleet. We should also define goods can be seen as one treatment regulations. However, how global transport should be of the main value-adding society is already demanding action performed in the most efficient activities a ship performs, even to address climate change and manner and not stare blindly at the human health concerns, so it’s likely ‘g/kWh’ or ‘pp’ values of exhausts from single ships. We need to stop “We need to stop taking for taking for granted that ships can granted that ships can use as use as much energy as they want 7 types of and travel partly loaded or empty much energy as they want” process waste: without any consideration for the environment. Oskar Levander ■■ T Transport Waste in shipping can be either ■■ I Inventory emissions to air and water, but it is though the transport of goods and ■■ M Movement also any activity that does not bring parts in a production process can ■■ W Waiting and delays value. For example, transporting be considered as a waste that should ■■ O Over production ballast water across the ocean does be minimised. ■■ O Over processing not really provide any useful value – Probably the biggest waste in the ■■ D Defects it is a waste of resources and, at the marine industry is resource utilisation same time, produces emissions. of ships, hardware and people. For
18 Rolls-Royce Indepth magazine Combining technologies for a quantum leap towards improved efficiency and less waste 7 types of waste in shipping
■■ I Inventory (goods stuck on ships or in ports/spares) ■■ M Movement (travelling too far/redirecting ships etc) ■■ O Over production and capacity ■■ W Waiting ■■ O Over processing (reloading/feedering etc) ■■ R Resource utilization (assets/ people/talent etc) ■■ D Defects – non availability
also a source of waste. Avoiding defects can be achieved by health management solutions based on artificial intelligence (AI) and by designing more robust and better validated systems. More standardisation on system level will allow cost efficient development of more reliable ships. As can be seen, many of the tools to reduce waste in shipping example, studies* show that bulkers and remotely piloting the ships from are coming from the latest ship in the Baltic Sea sail on average 34 a remote operation centre (ROC) intelligence developments and there per cent of the time in ballast. These when the captain’s expertise and skill is high potential to make the entire vessels can spend considerable time are needed. industry more efficient by adopting waiting at anchor or in port. Over-processing is another big these digital solutions. When accounting this, it means waste that emerges when the ship is In many cases, the best way that many ships are only transporting not operated efficiently as intended, to reduce emissions is not by cargo (or adding producing value) or the ship is not suited for the task squeezing more and more out of about 30-40 per cent of the time. It is at hand. Many ships drive at too the combustion technology or of course not possible to reduce the high speed to arrive early at port. the hydrodynamic design. It is by non-value add time to zero, but there Other ships use too many engines or ensuring that the assets and systems is a high potential to improve the too much power on the propellers. are operated in a manner that avoids utilisation rate. Providing optimisation guidance or consuming unnecessary energy By having a more holistic view by automating the process are good or resources – to ensure that all on the total transport demand, and ways to remove waste. For example, activities performed actually provide by providing active guidance to the the Rolls-Royce Autocrossing system real value to the end customer. cargo owners on cost, availability applied in many ferries in Norway is *Source: Magnus The key to achieving this is and timing, can the total transport a novel automation system that can Gustafsson, the new intelligent systems that Revolutionizing network be improved? Combine this help keep energy use low. short sea shipping, will enable a quantum leap towards with better optimisation of port slots, All kinds of defects that can Positioning Report, more efficient operation and Åbo Akademi cargo handling and arrival time and give rise to non-availability is University less waste. ● there is a big potential to reduce waiting times as well. Another big waste is resource utilisation of people and talent. There are thousands of highly skilled captains and officers that sit and watch an autopilot navigate a ship across a big ocean for weeks. The captain’s skills are really needed when entering ports and navigating narrow channels with dense traffic. The solution can be to go towards remote and autonomous ships and letting the automation handle the majority of the navigation
Rolls-Royce Indepth magazine 19 PRODUCTS
BTS is ideal for transporting wind farm technicians Our innovative new Boat Transfer System allows ‘daughter craft’ to be deployed from ships simply, quickly and safely – and all under full control
Winds By Richard White of change apid development of these vessels by deploying and other types of operation. of remote offshore smaller craft to quickly take BTS provides controlled wind farms means technicians to turbines in the launch and recovery, avoiding turbine technicians same farm or adjacent fields, traditional problematic single- are now stationed working in the same way as the point lifts and control ropes Rnearby for long spells on fast crew transfer vessels used involving crew intervention. vessels, transferring with their on installations closer to shore. At its heart is the cradle that equipment to turbines via walk- Spurring this development houses the boat. It is deployed to-work gangways. is the need to find a safer way using a single or dual handling The Boat Transfer System of launching and recovering unit and lifting winch. First, the (BTS) developed by Rolls-Royce daughter craft, lifeboats and handling unit transports it from can extend the productivity workboats, both for wind farms the stowed position inboard to
20 Rolls-Royce Indepth magazine DIFFERENT the vessel side, before the lifting VERSION winch then lowers it to below CAPABILITIES water level so the boat can be driven out and away. While the boat is afloat and in the cradle, LARGE the high perforated sides of the cradle restrain boat motions and dampen wave effects. The whole bow profile and stern centering device, together with the hull dampening units, 20 are shaped to fit the specific tonnes boat hull shape. They work together to ease docking and undocking, plus prevent damage when the boat is taken out of the The cradle is deployed water and vice versa. using a lifting winch Detailed mathematical models have been created for both wind 4.9 farm workboats and ships, and continues to be fully guided until duplications and redundancies. metres wide the performance of BTS verified it is deep enough for the boat to Depending on the configuration in the Offshore Simulator Centre float and depart under its own of the boat and the location of in Ålesund, with motions and power. This avoids the pendulum the BTS, personnel can go on MEDIUM interactions carefully analysed. effects of single-point lifts, or board from a platform at the side For recovery, the boat is the complication of dual lifts for of the BTS stowed position, at driven in to the open end of the larger boats, as well as hazards ship deck level, or over the bow cradle, which is U-shaped viewed from swinging hooks, and trim direct from a reception area in from above. The cradle is lifted effects from misplaced cargo.” the ship’s superstructure. Once and the boat settles on resilient BTS is rated for lifting people, on board, the only person who chocks which are tailored to suit with the necessary safety factors, needs to do anything is the 10 the boat; further lifting brings helmsman who drives the boat tonnes the cradle up to the point where out of, or into, the cradle. it is moved inboard to the stowed Three versions are currently position by the handling units. available. The largest is for No intervention is needed from workboats up to 20 tonnes with a people on the boat, who can maximum breadth of 4.9m, while remain seated in both launch the medium covers boats up to and recovery phases. 10 tonnes loaded, with a beam 3.8 Martijn de Jongh, Chief limit of 3.8m. The smallest is a metres wide Designer Ship Design and 3.5 tonne version for handling Systems, Rolls-Royce, says: smaller ribs and inflatables. SMALL “Both boat and cradle are fully Depending on whether the BTS controlled at all times during “Both boat and is to be installed on an open launch and recovery since deck or in a recess, either a the cradle is controlled by the cradle are fully knuckle boom or an overhead transfer system for the horizontal controlled at handling unit can be specified. movement, and the lifting winch If a ship with BTS has to controls the load and speed in all times during rescue survivors in the water or the vertical direction. launch and in lifeboats, a ‘trampoline’ net 3.5 “The cradle moves on can be rigged across the cradle tonnes vertical guides which finish recovery” on which people can transfer. above the waterline to avoid The cradle is held at a suitable adding resistance, but the cradle Martijn de Jongh level to match the net height, then raised to the ship’s deck. To meet the demand for smaller unmanned craft for research or other work, another version of BTS has also been developed. Man-lifting rating is not required, and the boats are typically smaller, so the system is simpler and cheaper. Some of The boat these craft are boat-shaped and is lowered can land on chocks, others have into the sea equipment or appendages below the baseline. ●
Rolls-Royce Indepth magazine 21 PRODUCTS A perfect balance With its unmistakable swept fin design, our latest environmentally sensitive areas, a special quad seal arrangement range of retractable stabilisers provide safe and ensures minimal risk of leakage, and steady navigation for ice-going ships the machinery is fully compatible with a wide range of environmentally he Rolls-Royce centreline.” He says that because the acceptable lubricants (EALs). facility in ice-class SAR system is based on the “The sealing arrangement and Dunfermline, proven, well-established Rolls-Royce compatibility with EALs mean the Read more about our Scotland, the core Aquarius and Neptune retractable ice-class SAR systems meet the partnerships on the Indepth of our stabiliser stabilisers, "both initial and requirements for VGP vessels, while mobile app product portfolio, operational costs are minimised due the low drag results in less fuel being Indepth for iPhone has introduced to the units being easily installed, the burned, which also benefits the is on the Apple the latest version of our Aquarius fin box being custom-designed to environment,” says Martin. App Store and on Google Play for Tand Neptune ranges of retractable exactly match the ship’s hull profile, Dunfermline has a long history Android devices stabilisers to allow ice-class ships to small hull opening and a simple in the manufacture of ship stability benefit from our Stabilisation-at-Rest reliable design". systems, dating back to 1871 in (SAR) concept. Recognising that the ice-class Edinburgh, when Brown Brothers Historically, ice-class ships have SAR stabilisers are likely to be was responsible for some of the most been unable to take advantage of the employed on vessels sailing in significant advances in steering gear. technology due to the potential for the stabiliser fins to break off during operations in ice. The Dunfermline development, however, retracts the fins into a custom-designed fin box, so there are no protrusions from the hull form, ensuring safe navigation through the ice. The SAR system, incorporated to both of these market-leading retractable stabilisers, employs active fin control technology and advanced hydrodynamic design to deliver higher levels of roll reduction “The fin when stationary and also maintain stabilisation performance while shape is under way. designed The new design has a reduced fin area and optimised lower fin to improve angle which meet the stabilisation performance requirements. The zero-speed new design also reduces dynamic performance, drag when deployed under way, which leads to lower fuel costs. The as more chord, stabiliser fin incorporates the proven and hence fin Rolls-Royce trailing edge design which eliminates vibration and noise. area, is behind Martin Cunningham, Managing Director, Rolls-Royce Motion Control, the fin shaft says this is because the one-piece centreline” fin construction offers simple maintenance, reducing through- life cost. He says: “The fin shape is Martin Cunningham designed to improve zero-speed performance, as more chord, and RIGHT: Dunfermline staff stand hence fin area, is behind the fin shaft proudly beside the stabiliser
22 Rolls-Royce Indepth magazine A perfect balance By Bill Thomson As sail gave way to steam, and then Today, Rolls-Royce commercial Since the 1930s, we have proudly to diesel engines, manual steering retractable stabilisers cover fin areas produced a range of naval non- became harder, and dangerous, and of 1.4m2 to 22.3m2 and derive from retractable stabilisers covering fin the Browns transformed the industry two basic families – the Neptune, for areas of 4m2 to 16.5m2, all fully- by introducing hydraulic steering cruise ships, ferries and commercial qualified shock proof and able to gear systems. The overcapacity in off-the-shelf (COTS) naval projects, survive arduous military operating shipping, and the consequent slump and the Aquarius, which is targeted 2 environments. A recent order has 22.3m in the inter-war years, then saw the at smaller ferries, cruise vessels maximum come from the US Coast Guard for company diversify into launching and large yachts. The Gemini non- area covered what will eventually be 25 offshore systems for aircraft from ships, and, retractable stabilisers are normally by stabiliser patrol cutters. significantly, a joint venture with used on offshore patrol ships, coast Naval ram actuator steering one of Brown Brothers’ old partners, guard ships and various COTS gear have been manufactured Denny Brothers, to build a retractable military vessels. since the 1940s, similarly shock fin stabiliser. qualified for military use, to various customers around the world. Current projects are delivering to the Royal Malaysian Navy for their Littoral Combat Ship programme and also to the Royal Navy for their Type 26 Frigate programme. While Dunfermline is also equipped to undertake regular and emergency maintenance and overhaul of a variety of marine equipment, it is the production of Aquarius, Neptune 25 and non-retractable naval stabiliser offshore units that is the facility’s mainstay. patrol cutters “There is no 'production line',” ordered by US says Cunningham. “Each stabiliser Coast Guard is different. Each ship, and each ship type, has different hull lines. Therefore, every order has to start from customer drawings of the individual vessel.” ●
To find out more, email martin. [email protected]
Rolls-Royce Indepth magazine 23 PRODUCTS PULLING POWER
Safer and more flexible tug operations are now At the time, Rolls-Royce had By Anette on the horizon, thanks to the new lightweight already made use of PM technology Bonnevie in propulsion systems, namely Wollebæk XT70 permanent magnet electrical motor tunnel and azimuth thrusters. The experience gained in their olls-Royce is towing in the full bollard pull range. development was useful because, expanding its This is instead of towing on a static in deciding on the winch motor, we portfolio of brake which is most common for this found there was no existing PM motor towing and escort type of vessel. The dynamic towing available that could virtually mirror winches developed capability of the low-pressure the performance of a low pressure specifically for hydraulic winch reduces risk during tug operations, a towing operation and also reduces The new XT70 PM introducing a new lightweight winch wear and tear on tow gear. Rdriven by a permanent magnet (PM) After winning the contract, electrical motor, named XT70 PM. the Deck Machinery team at Back in 2016, we won a ship Rolls-Royce looked further into equipment contract for several how winch systems for tugs could new tugs being built for the US tug benefit from using low pressure owner Edison Chouest. All 13 vessels hydraulics, and if an electro engine have now been delivered and are would benefit tug operators and equipped with towing winches plus their crews. PM-driven electro auxiliary winches from Rolls-Royce, all motors compare well with hydraulic based on low-pressure hydraulics. systems and offer high torque and The five largest tugs are equipped dynamic performance, as well as with winches capable of dynamic environmental benefits.
24 Rolls-Royce Indepth magazine THE XT70 PM IN ACTION
75 tonne pull on first layer
65 motor speed in rpm
70 nominal torque in kNm
170 operating overspeed in rpm
hydraulic motor. So we decided to three times its nominal rating with a Holmøy uses PM develop our own. third of the torque. The low gear ratio winches Less than three years ago we provides less gear losses and better launched a PM winch for fishing dynamic performance of the winch. vessels – the XT140 PM – which was In addition, when letting out lines, well received by the market. the winch can act as an electrical So far, the 10 winches in operation generator, contributing to the vessel’s to date have reported approximately energy needs. 32,000 running hours, with no Kjetil adds: “The PM motor can downtime whatsoever. Additionally, also provide regenerative power back 15 trawl winches with XT140 PM are to the ship’s switchboard, if the vessel currently on order. is so equipped. This feature makes it Kjetil Nilsen, VP Sales for Deck spills, improved efficiency reduces well suited for a hybrid ship system.” Machinery, Rolls-Royce, says: “As many the overall fuel consumption of the The equipment from the know, trawl winches are put under vessel, and the winch is designed to Rolls-Royce towing winch portfolio a lot of strain in extremely rough reduce installation and maintenance is also well suited to icebreakers conditions, so this track record of costs. It is also suitable for retrofitting. Read more operating in Arctic conditions as about our performance, with no down time, is The new XT70 PM render/ winches on well as to any vessel suitable for quite exceptional. The quality, robust recovery towing winch delivers an the Indepth emergency towing operation, such as mobile app construction and flexibility of these impressive 75-tonne pull on the first coastal and multi-purpose vessels. ● winches have quickly established them layer at 36 m/min. The motor has a Indepth for iPhone is on the Apple as firm favourites with major fishing nominal speed of 65 rpm (100 rpm at App Store and on Google Play for vessels operators around the world.” 690 VAC power supply) and a nominal Android devices The highly efficient electro motor torque of 70 kNm, but it can operate For more information, email reduces the risk of pollution from oil at an overspeed of 170 rpm – close to [email protected]
Rolls-Royce Indepth magazine 25 CUSTOMERS
By Patrik Wheater
Turning dreams into reality
Turkish shipyard Uzmar has come a long way since its humble beginnings more than four decades ago. Today it’s the world’s fastest builder of state-of- the-art tugboats – with Rolls-Royce at its heart as a vital supplier
26 Rolls-Royce Indepth magazine hen Harbour Pilot Captain Rolls-Royce's Erkut Aslanoğlu (left) Altay Altuğ went with Noyan Altuğ shoreside and set up a pilotage Wand towage services company in Turkey’s Çanakkale region, he may not have envisioned presiding over what was to become one of the world’s foremost builders of state-of- the-art tugboats. Some 45 years on and Capt. Altuğ remains at the helm of the business he started in 1973, although his son Noyan, as CEO, now oversees day-to-day operations of a company that not only operates 12 modern and 2005 – were built at a rented tugboats but also builds them. yard in Turkey’s shipbuilding hub Since the first Uzmar-built tug in Tuzla, on the outer fringes of was delivered in 1993 to its own Istanbul. But the Altuğs wanted their account, the yard has established own facility from which to make their itself as the go-to builder of quality mark in terms of production values tug and pilot boats. and corporate/cultural identity. The yard has delivered more “We were passionate about than 120 vessels – the majority of implementing a vision of an which built to Robert Allan designs advanced, modular-based serial – to customers that include Egon production method based on our Oldendorff, Smit, Abu Dhabi National experience of tug operations and Company, Kuwait Oil Company, building,” says Noyan. This vision Hidrovias do Brasil, Rio Tinto and manifested itself in 2005 with the the Suez Canal Authority, to name opening of the shipyard in the but a few. Kocaeli Free Zone, near Izmit. The Recounting the company’s first tug for export, Noyan Altuğ says he will never forget the date. “We signed our first newbuilding contract for three tugboats for ISKEN Port on 11 September 2001. Maybe it was the only contract signed in the world on that tragic day.” These first vessels – those delivered between 1993
Rolls-Royce Indepth magazine 27 CUSTOMERS UZMAR IN ACTION
Uzmar is now world renowned for its tugs – and (below) Noyan 120k is proud to show footprint in off a model of the m2 by end finished article of 2019
120 vessels delivered
20 annual tug build capacity
Uzmar Workboat and Tug Factory be a world leader in productivity, at a constant. However, with was born. sustainability and the adoption of many keels laid in the early to “We were keen to establish modern technologies,” says Noyan. mid-1990s, there are still as many our own culture as a company,” Uzmar is already the world’s fastest in need of replacement. he says. “We invested in young tugboat builder – an accolade “Ships are bigger, technology people, created a new system and bestowed on the yard in 2010. has advanced and new regulations 12 grew together as a team. You rarely have entered into force since modern tugs see this approach these days.” Adapting to market changes many of these tugs were built,” operated And grown Uzmar has. Since Despite market 2005, the facility has expanded fluctuations to include a 63,000m2 open area impacting with an additional 30,000m2 of builders of enclosed spaces and workshops. other vessel A new 15,000m3 enclosed building types, the hall is also under construction as tugboat market part of a US$10 million investment has remained in support of new contacts from resilient, the fisheries, and international according to military and coastguard sectors. Noyan. This, he By the end of 2019, Uzmar will says, is largely have increased its footprint to due to the 120,000m2, of which 45,000m2 will average age be enclosed, and have capacity to of the 17,500 build 20 tugs per year. tugboats in “In the future, Uzmar will operation, not only be the world leader in which has kept tugboat building but we will also newbuild orders
28 Rolls-Royce Indepth magazine Rolls-Royce propulsion is at “Our relationship with the heart of Uzmar's output Rolls-Royce is more of an alliance. We’re on the same side – we offer solutions to the final user” Noyan Altuğ
time and allow operators to make the quality of the systems on more precise observations of the board our tugs. surroundings and manoeuvring “Our customers demand the operations.” highest level of engineering and Rolls-Royce will, of course, sustainability combined with continue to play the same active competent after sale services.” role in tug technology development Some of the Uzmar projects since it began collaborating with Rolls-Royce is currently involved Uzmar back in 1995. in include the Robert Allan- “The relationship we have with designed RAstar 3200-W tug Rolls-Royce over many years is for SAAM SMIT CANADA, more of an alliance,” explains a joint venture partnership Noyan. “We’re on the same side – between BOSKALIS of the we offer solutions to the final user. Netherlands and SAAM SA of “For tugs, the quality of Chile. This tug will also be the says Noyan. “The marine the design and the equipment first in Canada to feature an transportation algorithm has installed is fundamental to IMO Tier III emissions-compliant changed according to the world’s maritime safety. Yes, there is propulsion and exhaust system. economic development.” competition as far as prices are As a result, it is also expected Indeed, just ten years ago, concerned but you cannot put a to become one of the most the largest containership had price on safety. We need to trust emissions-friendly vessels of its a 7,500 TEU capacity; today, type when it enters service. vessels sail with 20,000 TEU Uzmar is also building five or more. Another factor is the LNG-Ready tugs on order with change in emissions regulations Rolls-Royce azimuth thrusters and
Read more and port authority standards planning to build 20 tugboats for about our over recent years, which means speculation soon. Plans are also partnerships on the Indepth tugboat’s power systems and the in place to expand the Uzmar mobile app equipment have to change to product portfolio with patrol and
Indepth for iPhone meet the requirements. search and rescue boats. ● is on the Apple To this end, Uzmar is currently App Store and on Google Play for building IMO Tier III tugboats and Android devices is in discussion with a number of PAs and owners to build LNG- fuelled and hybrid tugboats. Noyan sees hybrid propulsion and autonomous operation as the future for the tug market, but says safety has to take precedence. “There must be a pilot on the vessel at all times to avoid risky conditions,” he says. “But data collection will be of great value for harbours and emergency stations. It will save
Rolls-Royce Indepth magazine 29 CUSTOMERS
By Craig Taylor A NEW DEPTH OF KNOWLEDGE Indepth visits Cammell Laird and the British Antarctic Survey to find out how the floating laboratory RRSSir David Attenborough will pioneer polar research for decades to come
housands lined the by NERC in 2015 to be the prime Antarctic Treaty, which dates back banks of the River contractor for the £200m project, to 1959. The treaty is recognised as Mersey to see beating off competition from one of the world’s most successful one of the most Europe and the Far East. international agreements. It enables advanced ships Rolls-Royce was subsequently Antarctica to be used for peaceful to ever be built in contracted by Cammell Laird for the Read more about purposes and gives the freedom the Sir David the UK, take to the ship’s design and the supply of a Attenborough for scientific investigation and co- water for the first time. range of equipment. on the Indepth operation. mobile app. TAt precisely 12:25 on 14 July, the Indepth visited Cammell Laird The Southern Ocean, surrounding Rolls-Royce designed RRS Sir David and British Antarctic Survey to find Indepth for iPhone Antarctica, covers 10 per cent of the is on the Apple App Attenborough edged down the out more about how this floating Store and on Google world’s ocean surface and contains Play for Android slipway at the famous Cammell Laird laboratory will pioneer polar devices some of the richest stocks of marine yard to mark the latest chapter in research for decades to come. life on Earth. the story of British polar research. Shipyard workers, engineers, Antarctica – a pristine scientists and maritime wilderness “This vessel is a state-of-the-art industry experts joined world- To understand the physical and renowned broadcaster Sir David technological demands placed on oceanographic research vessel, Attenborough, to celebrate the world’s most advanced research but it will also be a cargo this remarkable engineering ship, you have to first understand achievement. the environment where it will vessel, doing logistics and Commissioned by the Natural operate. transporting a huge amount of Environment Research Council Antarctica is the largest and (NERC), built by Cammell Laird and most pristine wilderness on Earth, goods down to Antarctica” operated by British Antarctic Survey located more than 10,000 miles (BAS), this is the largest civilian from London. Einar Vegsund ship to be built in the UK for The extensive research 30 years. undertaken is a collaborative affair, ‘Team UK’ working Cammell Laird was selected with 52 countries signed up to the in partnership The 129 metre-long vessel, of Rolls-Royce UT 851 design, will be Crowds watch the historic moment as completed in the coming months, the ship edges down with sea trials and its maiden the slipway expedition scheduled for 2019. Cammell Laird CEO, John Syvret CBE, said: “The RRS Sir David Attenborough, when built, will be one of the most advanced ships of its type in the world. Cammell Laird beat off international competition from around the world to win the contract, proving the calibre of its workforce and facilities. “The launch of the RRS Sir David Attenborough is a really important milestone in the build programme,
30 Rolls-Royce Indepth magazine A proud history of achievement
Cammell Laird is one of the most famous names in British industry with roots tracing back to the early 19th century. The business is located on the River Mersey, in the Liverpool City region, on the west coast of England. It is in the centre of a marine cluster, with direct access to many support services. It has a 120-acre site with four dry docks, a non-tidal wet basin, large modular construction hall and extensive covered workshops. Cammell Laird specialises in military ship refit, commercial ship repair, upgrade and conversion and heavy fabrication and engineering. It deals with a wide variety of projects ranging from specialist offshore conversions and fabrication, commercial ship repair through to the refit and upgrade of highly complex naval auxiliaries.
LEFT: The big moment (from left): Cammell Laird CEO John Syvret CBE, Sir David Attenborough, Professor Dame Jane Francis and Cammell Laird Managing Director Linton Roberts
and it’s a great day for the Cammell British Antarctic Survey Laird team. We have said that this Today, BAS is a world leader in Cammell Laird generation is proud polar science, maintaining the UK’s of its heritage and is determined long history of Antarctic discovery make its own history, and the and scientific endeavour. The UK’s launch of this Polar Research history of Antarctic expeditions laid Ship underpins this commitment the foundations of modern polar and ambition. I want to thank science. These included Captain NERC, British Antarctic Survey, Cook’s voyages of the 18th century, Rolls-Royce, Lloyds Register, to the famous expeditions led by Houlder Trust and the entire supply Scott and Shackleton. chain for their commitment and IMAGE: Agnieszka Fryckowska, British Antarctic Survey Its work dates back to World support. This is one team – ‘Team It has been a herculean effort The Sir David War II when a secret mission UK’ – working in partnership to by all to get here, this launch Attenborough to secure the UK’s presence in deliver a unique ship with unique raises the brand profile and as a will replace the the south also led to significant two BAS ships, capabilities and capacity. result provides increased global including the pioneering research. Employing “We are now back in the premier recognition, which bodes well for Bergen-powered more than 450 people, it operates league of the shipbuilding world. the future.” Ernest Shackleton three research stations in the
Rolls-Royce Indepth magazine 31 CUSTOMERS
The modular design Halley VI is the UK’s most isolated research station
Antarctic: Rothera, Halley and Signy. ROLLS-ROYCE Rolls-Royce winches with multiple It also carries out biological research IN ACTION types of scientific cable. Cleverly on the island of South Georgia. arranged in the small scientific winch BAS research has secured room, they allow the deployment invaluable data to help address of vital scientific equipment, either issues such as climate change, ozone over the vessel’s starboard side, aft, depletion and changing biodiversity. or through the moon pool. These BAS currently operates two include instruments for subsea ice-strengthened ships: RRS acoustic survey equipment, using James Clark Ross and RRS Ernest 129 up to 12,000m of wire, or to collect Shackleton, which is powered by length in seabed samples at depths of down Bergen engines from Rolls-Royce. metres to 9,000m. The new ship will replace the Einar Vegsund, Rolls-Royce Ship two current vessels in the coming Design, said: “There’s an extensive years. The UT 851 design features list of special items on this vessel. an extensive range of Rolls-Royce It’s a combination of all the duties equipment, including four Bergen it will do. It will be a state-of-the- The light area B33:45 diesel gensets, with double art oceanographic research vessel. shows the icy resilient skids or foundations. But in addition, it will also be a regions where The double resilient foundation 4 cargo vessel, doing logistics and the new vessel is a major contribution to the Bergen B33:45 transporting a huge amount of will operate vessel’s Silent R classification. In diesel gensets goods down to Antarctica. addition to the main engines, there are two main electrical tandem propulsion motors, propeller shafts, propellers, rudders, steering gears and winches. Rolls-Royce is also supplying the motors and drives for the four thrusters. Captain Will Whatley, who has 2 been working in the polar regions main electrical for the last 10 years, will command tandem the new ship. He said: “We’ve got a propulsion ship here that’s got lots of features motors designed into it to mitigate the hazards of the polar regions and make the job as easy as possible. It’s bigger and we hope it will be a smooth ride across the Southern Ocean. Certainly, from the model tests it looks good. “The quality of the research is 4 enhanced greatly by a very quiet thruster acoustic noise signature, and motors and that’s been one of the main design drives features of this ship.” There are many different
32 Rolls-Royce Indepth magazine The greatest possible honour
When, 100 years ago, this country sent people down to the South Pole, we were the pioneers of exploring Antarctica. When we did so, I suspect the reason was the South Pole seemed as far away and as desolate and as empty as you could possibly get on this planet. Now, 100 years later, we realise “The quality of that although we now know a great the research deal about what goes on down there, now we realise that that is enhanced remote place is in fact key to the greatly by a whole understanding of our planet. What goes on down there very quiet affects the whole of the earth on which we live. acoustic noise The British Antarctic Survey signature, and is an organisation of marvellous people, of which this country that’s been one should be hugely proud. And of the main what they discovered is that the Antarctic, far from being design features remote and desolate, is key to of this ship” the understanding of what is happening to the entire globe. Our concern about the health Captain Will Whatley of our planet is essential, because our planet’s in such danger and the key to discovering how to help and understand what the problems are, are not just up here in the northern hemisphere and in the temperate regions, it’s at the Poles, both North and South. "All of this has to be done with fully understand the complex And so that our future and the best comfort and efficiency, so environmental changes in the everybody’s future will be this is a huge challenge for us as polar regions. affected by what people working ship designers.” “This ship, with Rolls-Royce on this ship, British scientists The new ship will transform design, will help us explore new and others, will be discovering in research capabilities, as Professor places so that we can understand years to come. Dame Jane Francis, Director of our world better, especially the So as far as I am concerned, to British Antarctic Survey explains: deep polar oceans that are so see this magnificent hull, with my “It really will be a step change in vital to our understanding of how name on it, is the greatest possible how we operate, supporting UK our oceans and atmosphere are honour, and I thank everyone who science in both the Arctic and responding to climate change. has been involved in this wonderful Antarctic. It has longer endurance, This new information will help enterprise and wish them huge and has high-tech scientific us look after our planet more success when this equipment on board. carefully in future. marvellous ship gets “We’ll be able to undertake "The Sir David Attenborough is down there. science in more remote areas an amazing ship and I hope it will than we’ve ever been able to inspire future generations. Sir David The Sir David go before. "This ship, with its Rolls-Royce Attenborough "We will be able to take more design, will take us to places that Attenborough, is specially scientists on board, so that means we haven’t been and help us to speaking at designed to we can do multidisciplinary understand our world better so launch ceremony deal with the science. There’ll be several that everyone can make better extreme polar conditions projects working together, decisions and we can look after which is what we need to do to our world in a better way.” ●
Rolls-Royce Indepth magazine 33 PROPULSION
Hurtigruten’s new expedition cruise ships will feature possibly the world’s most efficient propeller system CRUISE CONTROL he Kleven Verft take into account the propulsion By Anette motor in an electric, gas, hybrid shipyard in Norway system. With a four per cent higher Bonnevie or battery-driven system. The is busy building two efficiency rate – 10 per cent at lower Wollebæk introduction of PM technology has environmentally- speeds – Hurtigruten stands to made them even more efficient. friendly expedition achieve major savings. The new Azipull-PM has been cruise ships for Each of the ships will be fitted on the market since 2017. It is Hurtigruten, the with two Azipull main propellers configured for L-drive operation, company that operates Norway’s from Rolls-Royce that have been which largely uses the same Ticonic coastal ferry service from further developed to incorporate underwater unit as before, but Bergen to Kirkenes. In addition permanent magnet (PM) motors. is equipped with a vertically- to a hybrid power system, their Azipull thrusters are pulling axled PM motor integrated into main propellers represent a green propellers, housed in a streamlined a new upper unit. innovation, one that will provide both underwater unit, and have been “The new PM electric motor has environmental and financial benefits. providing effective propulsion and an extremely high efficiency rate The new vessels, MS Roald manoeuvring for various types of over a wide range of rotational Amundsen and MS Fridtjof Nansen, vessels since 2003. speeds,” says André Landes, will be powered by Rolls-Royce’s To date, Rolls-Royce has Product Manager for Azipull PM hybrid system, which combines produced 550 of these units in at Rolls-Royce Marine. batteries with highly efficient diesel Norway. They operate either by engines. The environmental gains direct mechanical transfer or are increase even more when you powered by a separate electric “We have never seen commercial motors of this output and speed class with such a high efficiency rate”
Sigurd Øvrebø
“Excellent hydrodynamic efficiency, along with lower mechanical losses with the new PM-L drive line, make a really profitable combination.” Hurtigruten will benefit from the The amount of space required in new system the thruster room is also reduced
34 Rolls-Royce Indepth magazine Key facts: AZP-PM L-drive ■■ Installation is quicker and easier with the newly developed hull attachment. This cylindrical steel component with a conical part on the attachment flange is easy to weld to the hull structure, particularly for a thruster that The new Azipull PM must rotate in all directions. electric motor largely uses ■■ The range comprises three the same underwater unit as before, but is equipped different propeller models, with a vertically-axled depending on the vessel and PM motor that's integrated its planned usage. All sizes are into a new upper unit available in today’s existing Azipull models. ■■ If the AZP-PM L-drive unit is combined with a fixed-pitch propeller, the rotational speed is controlled by varying the power to the motor. With controllable pitch (CP) propellers, it is possible to vary both the number of rotations and the pitch of the blades using Rolls-Royce’s propulsion control system, thereby achieving optimal operational performance. Hurtigruten has ordered CP propellers. ■■ Azipull can also be ordered with a propeller hub that allows the blades to be fully feathered while sailing. This minimises the resistance from an Azipull unit that is not being used. When the ship is sailing at low speed, it may not be necessary to have more than one Azipull unit in operation. 98.6% 550 This is a major advantage efficiency rating Azipull units for energy conservation on for 120 PM motor produced multifunction vessels.
because the new thruster is DNV GL. This means that the Azipull best electric motors. We have never compact. The PM motor lies within 120 PM motor is classified as meeting seen commercial motors of this the diameter of the housing, which the highest international standard for output and speed class with such avoids the complicated wiring and energy efficiency for electric motors, a high efficiency rate.” anchoring of the separate motor IE4 – Super Premium Efficiency. needed with a conventional Z- or In the new L-configuration, the Fuel savings C-drive electric configuration. top gear and the classic induction Although the vessels’ actual André adds: “Typical areas of motor has been replaced by a top- performance profile will not be application will be offshore supply mounted PM motor. In tests, the known until they have been in and service vessels, support ships, latest edition of the AZP120-L has operation for a while, the basic offshore stand-by ships, coastal demonstrated an improved efficiency data from another Hurtigruten ship, tankers, car and passenger ferries, rate of around 4 per cent at nominal Fram, shows that the propellers as well as cargo vessels and and more than 10 per cent at low generally operate at partial cruise ships.” loads. Also, removal of the top gear load, where the new solution is has made the motor much quieter. particularly favourable. World-class efficiency “This is a fantastic result,” says Initial calculations for typical The new Azipull 120 PM motor was Sigurd Øvrebø, General Manager operations in Arctic areas show that recorded as operating at a 98.6 per for electric and power products at it could be possible to save around cent efficiency rate during recent Rolls-Royce. “Our team has supplied £70,000 (NOK 750,000) per year in joint tests by Hurtigruten, Kleven and Hurtigruten with two of the world’s fuel costs. ●
Rolls-Royce Indepth magazine 35 NAVAL
THROUGH
The Littoral Combat Ship has been in service for ten years
36 Rolls-Royce Indepth magazine By Craig Taylor
The MT30 marine gas turbine has been at the top of its game for 10 years now. We look at where it’s left its considerable mark…
t’s ten years since the MT30 first powered Business Development. “It’s an engine that, in the US Navy’s Littoral Combat Ship (LCS) the main, is being selected for platforms that USS Freedom. Since then, and with a have been designed in the 21st century, and it growing demand for power across the will be powering them for the next 50 years.” world’s navies, the world’s most power- Many factors have converged to lead dense in-service marine gas turbine is to the success of the MT30 during its first finding favour across the globe. decade, not least its aerospace heritage. Typically rated between 36MW to 40MW “The MT30 is derived from the Iat 100°F depending on application, and with Rolls-Royce Trent aero family," adds Sam. 100 per cent power-retention through-life, "Its aerospace parentage has played a key the MT30 powers some of the world’s most part in the success of the engine, not only in advanced naval ships, from the stealthy, agile its selection by a growing number of navies, and fast LCS to the Royal Navy’s largest-ever but also in the performance we’ve seen over warship, HMS Queen Elizabeth. the past decade." MT30 offers a superior power-to-weight By taking the best of what existing ratio, generating up to 40MW from a aerospace technology can offer, the MT30 30-tonne packaged unit, including most draws on more than 50 million flying hours of the auxiliary systems. It gives navies of proven reliability which carries across more power in less machinery space than into the marine variant. It’s not just reliability alternative engine types, and offers ship though, as Sam explains: “By sourcing the designers much more options and flexibility engine from our aerospace business, we can in designing the naval vessels of tomorrow. really offer a competitive engine. Most of The MT30 also supports the ‘lean manning’ the design and development work is done concept by virtue of its ultra-low on-board by our teams in aerospace. There’s a robust, maintenance requirement. global supply chain and obsolescence is not “It’s an engine for the modern era,” an issue, with a significant installed customer says Sam Cameron, Senior Vice President, base across the two sectors.”
Rolls-Royce Indepth magazine 37 NAVAL
A proud record “It’s been 10 years since Littoral Combat Ship (LCS) 1, USS Freedom, joined the fleet as the lead ship of her class," said Joe DePietro, Vice President, Small Combatants and Ship Systems, Lockheed Martin. "Since that time, the Freedom-variant LCSs have accumulated more than 420,000 nautical miles under the keel. "The Freedom-variant LCS has become a true operational asset to the US Navy, having completed multiple operational deployments and integrating increased capabilities such as The HMS Queen Elizabeth the Surface-to-Surface Mission Module (SSMM) that was successfully tested earlier this Five navies, seven ship types The US Navy was the first summer to advance capacity To date, five navies have selected customer. “This was a hugely to prevent multiple swarming the MT30 to power a variety of ship significant breakthrough for surface threats. types, evidence of its versatility: Rolls-Royce,” Sam says. “The break "We are continuing to increase ■■ US Navy (Freedom class LCS, into the US market with a prime the capability and lethality of Zumwalt class DDG-1000 mover gas turbine, set the scene Read more the class, and are proud that LCS Destroyer) about the for the future success of the engine, remains the fastest and most ■■ Royal Navy (Queen Elizabeth MT30’s decade and made other navies sit up and of success on affordable ship in the US Navy class aircraft carrier, Type 26 the Indepth take notice. mobile app. fleet, with five ships delivered global combat ship “The LCS programme had a to date and two more slated for ■■ Republic of Korea Navy (Daegu Indepth for iPhone high-power requirement, to enable is on the Apple delivery this year.” class frigate) App Store and on the ships to reach their impressive ■■ Italian Navy (Landing Helicopter Google Play for top speed, which is in excess of Android devices Dock (LHD) 40 knots. The combination of Building trust for the long term ■■ Japanese Maritime Self Defence twin MT30s and four Rolls-Royce With ten years of operation under Force (30FFM frigate) waterjets was the perfect match.” our belts, the MT30 is developing a track record of high reliability and emulating the success of the aero-parent. Naval shipbuilding is a very long-cycle business, and with today’s new ships expected to operate for between 30 and 50 years, the propulsion system on a ship is there for the long haul and must be adequately future-proofed. Choosing the right propulsion system is a crucial decision and it has to be the right one to ensure a ship will still perform as its systems and capability are upgraded throughout its life. That’s one of the key strengths of MT30. It has the power for today and also tomorrow. With growing demand for electrical power, for example, you need a power source that can meet those future demands. The MT30 is operating or has been selected in all conceivable propulsion arrangements – mechanical, hybrid and integrated-electric, with power delivered to water-jets, controllable and fixed-pitch propellers, depending on application.
38 Rolls-Royce Indepth magazine Powered by two Rolls-Royce THE MT30 MT30 gas turbine generators, IN FIGURES together with two smaller RR4500 models, the Zumwalt class destroyer was the next platform to feature the engine. It’s an all-electric ship at the cutting edge of naval technology, and combined the four gas turbine generators provide almost 80 megawatts of power to the ship 40MW with its impressive array of high max power tech systems. generated from In the UK, the Royal Navy a 30-tonne selected MT30 as the prime mover packaged unit for its 65,000 tonne displacement Queen Elizabeth class aircraft carriers with integrated-electric propulsion. Each ship will generate 109MW, with a pair of MT30 gas turbine generator sets accounting Building the MT30 for 72MW. A single MT30-based hybrid arrangement will also power the UK’s 100% “It’s being selected for decade as the Type 26 City Class global combat power- first rung on the ships, the first of which is in-build. retention platforms that have been ladder towards Drawing on the high-power density through-life establishing attributes, the Republic of Korea designed in the 21st century MT30 as the Navy (RoKN) also selected a single and will be powering them engine of MT30 in a hybrid propulsion system, choice for naval specifically designed to enhance for the next 50 years” propulsion,” Anti-Submarine Warfare capabilities. says Sam. “We’re The first Daegu-class (FFX-II) frigate Sam Cameron now moving was duly handed over to the navy onto the second earlier this year, following successful rung. Seven ship sea trials. 10 Development, South Korea, says: types are using MT30, and so far, Jay Lee, Rolls-Royce, Vice years of “The selection of MT30 for the five navies have chosen it for their President Sales & Business operation second batch of ships really was major programmes. a game-changing decision that has “I firmly believe that the next transformed capability, especially decade will see MT30 further in terms of achieving the ultra-low establish its position and reputation, noise requirement ASW operations.” and as more navies gain more High power output again became experience in operating the engine a key factor in the Italian Navy’s that all-important trust continues selection of MT30 to power its future to build.” ● flagship Landing Helicopter Dock (LHD). Two MT30s will power the new 20,000-tonne displacement multi- For more information, email purpose amphibious vessel. [email protected] This year, the Japanese Maritime Self Defence Force selected a single MT30, in a combined diesel and gas (CODAG) configuration, for its 30FFM frigate. The addition of Japan means that the three largest users of marine gas turbines, have all endorsed the capabilities of the MT30 and selected it to power significant future programmes. Most recently, the Royal Australian Navy selected the BAE Systems Global Combat Ship- Australia as the preferred design for The Republic of Korea Navy its nine-ship SEA 5000 programme. (RoKN) selected an MT30 for its new Daegu-class frigate Future potential The USS Zumwalt “In some ways, we look at this first
Rolls-Royce Indepth magazine 39 SHIP INTELLIGENCE
By Patrik Wheater
Anu Peipo (seated) and the team bring years of at-sea experience
is very beneficial for the Ship Intelligence development team at Rolls-Royce. “We can really help redefine the way ships are operated; how whole tasks can be carried out ashore, compared to how they are currently done onboard. It’s about introducing totally new systems and user All hands interfaces for navigators, engineers and captains and recreating the work processes around them.” While the seafaring team will initially provide the information and experience on deck required to better understand ship-human interactions, the appointment is widely seen olls-Royce has appointed as portent of how ships will be operated in a team of former seagoing the future. officers to provide practical Kevin Daffey, Rolls-Royce Director insight into how ships can be Engineering & Technology – Marine, said: safely operated remotely. “What we see is a future in which more of The four-person team – two the tasking is transferred from the vessel navigating officers, a marine engineering to shore. Rofficer and a pilot – will feed information “As an example, instead of every ship based on their hands-on seagoing experience having a highly trained chief engineer into the Rolls-Royce Remote Operating onboard, why don’t we have one or two of Centre (ROC) product development at their them shoreside, working in a shift pattern and New team of experienced Remote & Autonomous Ships R&D Centre being able to go home to their families every officers marks another in Turku, Finland. day, and providing expertise and guidance step forward in the Anton Westerlund, Technical Product to those less well-trained crews onboard Manager, ROC, a Chief Officer with more several ships? development of the than ten-years’ sea-time, explained: “Coming “The rationale of bringing in seafarers to autonomous ship concept from a vessel to a shore-based installation help develop ROCs is that we can design the
40 Rolls-Royce Indepth magazine right interface between the human and the "Young people can relate to it and machine and that interaction becomes really younger engineers can relate to it, especially important. Designers can engineer functional given what’s happening in the automotive and interfaces, but you need the end-user to rail industries." explain how best to utilise that technology; Kevin adds: "It’s all about attracting bright to explain how it fits into the actual operation and enthusiastic people to our industry – and of a vessel. autonomous shipping can attract talented “The ROC now has a seafaring team and innovative people from other industries to show us how best to operate a vessel to consider the maritime industry as a career.” remotely, in the safest and most effective Anu also believes the advent of way possible. We can’t do that alone – autonomous ships and shore-based ship autonomous ships will still need a tight control centres will encourage more females collaboration between seafarers, navigators to consider the maritime industry as a viable and marine engineers.” career path. Anu Peipo, Work Process Engineer, “Let’s assume the male to female ratio at Remote & Autonomous Operations, a former sea is one in ten, I think this new ship working Second Officer and Dynamic Positioning environment could result in a 50:50 split,” Officer on tankers and offshore vessels, she says. says: “The remote operation of ships will “I have two children so a job ashore was undoubtedly be more attractive to younger very appealing. My first thought when this people considering a career in the maritime opportunity came up was that is something industry. Introducing this way of operating that you cannot miss. When you get the ships remotely will make this industry much chance to be involved in something like this, more appealing, more interesting.” to create something totally new, something no The wide appeal of this maritime future one has done before, then that’s something is underscored by the number of applicants you want to be involved with.” Rolls-Royce received for Engineering Anton Westerlund agrees: “The ROC positions at their Remote & Autonomous is great place to work. It really is a new Ships R&D Centre in Turku challenge, but we are creating something that “When we advertised for these roles, we currently does not exist. had over 1,000 applicants,” says Kevin. “This "We have a fantastic, highly-motivated, was because we set out a vision of what cross-functional team. We have so many remote and autonomous ships could be, and professionals from different backgrounds you people bought into that. can always find somebody who can help you. We have a chief engineer and a pilot, so we have a wide range of seagoing knowledge “The centre is a great place and experience. “Basically, every day somebody will come to work. We are creating up and say, ‘Hey, how is this done onboard? something that currently How did you do sort this problem out onboard?’ They very much appreciate us does not exist” being here.” ●
Anton Westerlund For more information, email [email protected]
The team demonstrates the many capabilities of Ship Intelligence
Rolls-Royce Indepth magazine 41 SPECIAL FEATURE Still going strong
By Bill Thomson
Kamewa waterjets in action
1849 1860 Evolves into Kristinehamn Kristinehamn Mekaniska diversifies into steam- Werkstads Aktiebolag driven machinery and shipbuilding
Karlstad Mekaniska Wagon repair shop Werkstads (KMW) Kamewa set up Kristinehamn, founded in Karlstad, timeline Sweden Sweden 1850s 1860s
42 Rolls-Royce Indepth magazine As the 10,000th Rolls-Royce Kamewa waterjet enters service, we look back over the history of this versatile propulsion unit – and Still going strong its wide range of applications
amewa’s origins Mekaniska Werkstads Aktiebolag, or In parallel with this development, date from the Kristinehamn Mechanical Works Ltd. a factory in the neighbouring town, establishment of By 1867 the works had turned Karlstads Mekaniska Werkstad, had Sweden’s railways, to the production of steam been manufacturing simple water- and the setting up locomotives and steam-driven driven turbines. Its own factory was of a wagon repair agricultural machinery then steam unable to keep up with the demand, shop in 1849. This engines and boilers for ships. It was so the Kristinehamn works began workshop grew over the years, a small – and logical – step to manufacturing turbine parts under Kand evolved into the Kristinehamn diversify further into shipbuilding. contract, an arrangement that led
1880s 1913 1970s Kristinehamn bought Kamewa launch by KMW, who become controllable pitch known as Kamewa propeller (CPP)
Kristinehamn makes Kamewa granted Kamewa launch water-driven turbine sole rights to make their tunnel and parts for KMW the Kaplan turbine azimuthing thrusters 1880s 1940s
Rolls-Royce Indepth magazine 43 SPECIAL FEATURE
to its purchase by KMW-Karlstad. A waterjets. It is a journey that began significant development in 1913 gave in the 1970s in Kristinehamn and in the company sole rights to the Kaplan the early 1980s in Kokkola, Finland. turbine, which used adjustable blades, For some time, the Swedish Kamewa allowing a constant power output and Finnish FF Jet lived in parallel. regardless on flow. Kamewa was able to refine and The Kaplan turbine provided the develop its steel series for larger inspiration for the controllable pitch applications such as fast ferries, (CP) propeller for ships and the larger patrol boats and super yachts. Kamewa CP propeller was launched “FF Jet, meanwhile, continued on the market in the 1940s. to develop its aluminium series Kamewa’s production expanded for smaller fast boats. Its first further with the introduction of involvement with waterjets came tunnel and azimuthing thrusters in the during its boatbuilding phase, when 1970s, which added to the company’s it started building small vessels for success. At the same time, Kamewa’s the Finnish Navy. These craft were engineers began to look at producing specified with Hamilton waterjets, their own waterjet propulsion units, and after a while we figured, ‘Why based on the company’s considerable can’t we do this as well?’ turbine expertise – after all, a waterjet “Moreover, the Finnish Navy is, effectively, a turbine in reverse. preferred to use locally-produced Today, the Kamewa products equipment rather than import from Rolls-Royce have secured the something from the other side of the largest share in the global waterjet world. Thus, the FF Jet was born. propulsion market. "We started as an aluminium Fredrik Appel, General Manager boatbuilder, then added aluminium Product Waterjet at Rolls-Royce, waterjets for vessels such as small Kristinehamn, Sweden takes up the patrol craft and eventually dropped story. “Kamewa has two basic families the boatbuilding side to concentrate of waterjets,” he says. “There is the on the waterjet work.” small FF Jet and the larger steel Alongside the smaller waterjets,
Fast attack craft in Trinidad and Tobago
“With increased focus on product development, we are maintaining the most attractive portfolio and continue to grow within the high-speed segment”
1980s 1989 Kamewa acquired by Kamewa launches British firm Vickers, broader portfolio, who later acquire FF Jet including the A Series
Pair of 1,000kW FF Jet developed waterjets fitted to in parallel in King of Spain’s Kokkola, Finland private yacht 1986 1996
44 Rolls-Royce Indepth magazine “Today, we have the market’s most efficient pump Finland’s landing craft benefit from in the S4 Series of waterjets” waterjet agility
Kamewa installed its first waterjet in turn acquired by Rolls-Royce. catamaran Tangalooma Jet, the luxury on a Swedish naval landing craft in By 1996, Kamewa had laid yachts Mangusta 94 and Mangusta 1971, and a second on a gas-turbine the groundwork for meeting 165, Förde Reederei Seetouristik’s new leisure craft belonging to fleet the market needs with a much Heligoland ferry and a myriad of owner Wilhelmsen. broader portfolio. The A Series, an patrol vessels for various navies. Subsequent tests with larger aluminium SII pump, was developed More recently, in March, Rolls-Royce ships concluded that waterjet for the smaller sizes to get the was contracted to deliver Kamewa propulsion was best suited to high- benefits of mixed-flow technology. waterjet propulsion units and Series powered ships capable of speeds of “Demand grew significantly in 2000 MTU engines for three 42m more than 25 knots. Various orders between 2006-2008,” said Appel. high-speed, lightweight carbon fibre for high-speed craft propulsion “Today, we have the market’s most ferries undergoing construction at the followed, and the company’s efficient pump in the S4 Series of Brødrene shipyard in Norway. position was cemented by fitting waterjets and a very cost-effective And now, with entry into service a pair of 1,000kW waterjets for product in our S3/CA jet (formerly Read more about of the Seastreak Commodore, which Rolls-Royce the King of Spain’s private yacht A3 and the same pump as S3). waterjets on the completed sea trials in May, marking and the Gentry Eagle, a Kamewa- “With increased focus on free Indepth the 10,000th reference for the mobile app. powered racing craft which crossed product development, we are Kamewa waterjet, this relatively recent the Atlantic at an average speed maintaining the most attractive Indepth for iPhone development in marine propulsion is is on the Apple App of 48 knots in 1989, reaching a portfolio and continue to grow Store and on Google well and truly established. Play for Android maximum of almost 70 knots. within the high-speed segment.” devices The vessel, the largest and In 1986 Kamewa became part Today, Kamewa’s steel waterjets fastest vessel in the New York-based of the Vickers Group, who then power numerous high-speed operator’s fleet, is powered by four also acquired FF Jet in 1994. ferries and military vessels, clean burning Tier III 12V4000M64 The two waterjet families became including the US ‘Freedom’ class MTU diesel engines driving four more closely integrated, which Littoral Combat Ships (LCS). Rolls-Royce Kamewa 63S4 waterjets. ● has continued since Vickers was Other references include the fast
For more information, email [email protected] 1999 2018 Waterjet demand grows significantly around the globe
The Vickers Group The 10,000th Kamewa is acquired by waterjet is fitted to Rolls-Royce Seastreak Commodore 2000s
Rolls-Royce Indepth magazine 45 HEALTH MANAGEMENT
The new advanced Health Management system harnesses the power of data to give a detailed and holistic overview of the wellbeing of onboard equipment and systems
n an exciting new collaborative venture across many of our disciplines and locations, the Rolls-Royce Ship Intelligence team has developed a pioneering new solution that could help revolutionise the way customers manage their assets. IRolls-Royce's new Health Management (HM) system makes use of an often-overlooked and undervalued resource – data. Modern ships are full of sensors and information technology systems; HM manages these large data sets, using advanced machine learning technology, via the Cloud. It leverages condition monitoring techniques from our vast aerospace experience, using scalable techniques such as machine learning, edge computing and a Cloud Internet of Things (IoT) platform. “This pioneering new solution revolutionises the way our customers manage their assets,” explains Technical Product Manager Per Huse. “By providing them with vital insight into their ships’ equipment The ship’s doc or and systems, thus reducing costs capsulated into machine learning By Bill further analyse the data. This gives and unnecessary downtime, we truly models that we deploy to the ship.” Thomson customers’ fleet managers information place the end users at the heart of This gives customers real-time about the functioning of their ships’ what we do.” access to key information about the equipment, as well as access to This fresh approach offers health of their onboard equipment insight and first-hand advice from advantages to Rolls-Royce as well as and systems. As well as a mobile specialist engineers. our customers. “The enhanced data dashboard on the ship, the same Our vast portfolio of designed collection and product understanding information is sent through a and manufactured equipment and will allow our design teams to further customer portal on shore. The final systems, and a leading position in improve the quality of our equipment application of HM is the Tech Portal system integration, puts us in a unique and achieve a better understanding within Rolls-Royce, where support position in monitoring and overseeing of our customer, in a fully data-driven personnel and data scientists can equipment health. way,” continues Per. Our engineers and scientists can “Our solution tap into a vast amount of industry Data is exemplifies sharing knowledge, so as well as our own provided on of best practices all areas of systems, HM can offer insight into the within the Group. We operation health and operation of third-party have built a generic equipment and systems, including end-to-end platform that supplied by competitors. The for secure collection, next stage will see it integrate with transfer, storage and Energy Management (EM), adding a analysis of ship data. powerful and comprehensive tool to Lessons learned from cut downtime and fuel emissions to machine analysis the core equipment health monitoring of these large data capabilities. “This technological base sets in the Cloud are is set to transform the industry by
46 Rolls-Royce Indepth magazine “With the focus on general equipment we can deliver much more than single engine or thruster monitoring; we can achieve a holistic view of any vessel”
Anders Paulsen
methodologies. This means that we limit the development planning to a few weeks and have tactical flexibility of how to prioritise.” The HM project is the first of its type for Rolls-Royce Marine in many ways. It's our first fully-fledged IoT platform created in the Cloud; the first to employ machine learning and build artificial intelligence on large data sets; first to create an Edge computing platform at the vessel/installation; and first to create a secure, fast and stable two-way communication between ship and shore that also accommodates poor bandwidth scenarios. The experience and lessons learned will provide a foundation for future projects in terms of knowledge transfer, extendability of platforms The new HM and the applications developed. It's system is already also been a truly collaborative effort, monitoring with Product Centres, Automation and 50 engines in Control, Ship Intelligence and 11 locations Rolls-Royce Digital all pulling together, collaborating across sites in Bergen, Ålesund, Finland, UK, Italy and The ship’s doc or the US. The project’s Cloud-based providing our customers with insight tailored to their needs. Early customer collaboration tool has also tracked into their equipment and systems like interaction opened opportunities tasks, activities, progress never before and helping them to to soft-launch a pilot on land-based and documentation. reduce operating, maintenance, and installations. And the agile and The solution applies modern downtime costs,” says Anders Paulsen, iterative project execution meant the architectural principles that provide Head of Research and Technology. launch of parts of the solution while scalability, extensibility, and security of “With the focus on general equipment the rest of the build continued. data. By applying machine learning to we can deliver much more than single This has provided valuable the collected data, real-time analysis engine or thruster monitoring; we can feedback to the project team, but and alerts are provided to the crew achieve a holistic view of any vessel.” equally important, has created on the vessel, while shore-based One remarkable aspect of HM is business value to Rolls-Royce and management are given warnings the speed at which it's been delivered. its customers. Specifically, we've of imminent issues and trends that Originally scheduled for 2020, the demonstrated an ability to detect indicate a future problem, and the data project has shifted gears so that engine anomalies early and take is shared by Rolls-Royce experts who completion has been achieved in the proactive measures. More than 50 can be called upon to advise. first quarter of 2018. engines are currently monitored in Essentially, Rolls-Royce customers The user interfaces and concept 11 distinct locations. can now perform predictive have been piloted with customers all Key to the rapid development has maintenance and operate more over the world – first through clickable been the project management. Anders safely. Additionally, HM highlights design prototypes, later through explains: “The project's been run by any inefficiencies in operation and application prototypes. an agile methodology that's part of provides empirical advice for cleaner Considerable focus was put on the lean thinking framework. It's been and more cost-efficient operations.● customers from the start, with a governed by an overall goal, with collaborative pilot program, regular activities and tasks managed using customer focus groups and frequent Scrum and Kanban, two different, but For more information, email feedback ensuring the end-product is closely related project management [email protected]
Rolls-Royce Indepth magazine 47 SERVICES
Canaries flying high
By Craig Taylor
48 Rolls-Royce Indepth magazine The Rolls-Royce facility is located within the Astican Shipyard
he first half of The Rolls-Royce Service workshop in the Canary 2018 has seen a significant increase Islands is realising its full potential as the offshore globally in thruster Exploration & Production market finally begins to overhauls compared flourish again after a couple of challenging years to the previous year, as rig owners continue to prepare for their Opened in 2015, the 2,100m2 owners, as well as merchant, ropax, Tnext contracts. facility is fully equipped to deal with fishing vessels and the local ship- Located within the Astican the growing demand from offshore owning community. Shipyard, in the growing maritime customers. In a unique partnership The co-location in the yard has cluster of Gran Canaria’s port of with Astican, the workshop has an added benefit for owners, in Las Palmas, the Rolls-Royce Service been optimised to carry out major that it offers the combination of Canaries workshop is now benefiting from this service operations on all Rolls-Royce Rolls-Royce capability and specialist upturn in Exploration & Production equipment, with a strong emphasis knowledge of products, together (E&P) activity. to support rig, drillship and offshore with the close proximity to the deep- water quay and the extensive repair and overhaul facilities of Astican. Pool offers depth of support tunnel thrusters, or just a single Commenting on the success of thruster, as part of a planned Las Palmas, Nils-Reidar Olsvik Valle, In response to our customers’ maintenance solution. Vice President Customer & Sales, flying high needs, Rolls-Royce has, for several Las Palmas plays a key role Rolls-Royce, says he believes it’s years operated a thruster support in this continued success, along down to three key factors: “Firstly, pool. This provides replacement with our other Service workshops it’s the location. The physical spot on units, enabling the exchange of a in Ulsteinvik, Norway and Gdańsk the map has been key to our success, complete shipset of azimuth and in Poland. and that was a prominent fact when we original decided to invest here.
Rolls-Royce Indepth magazine 49 SERVICES
“Las Palmas lies on the key transit ABOVE AND routes between Northern Europe, RIGHT: 2018 West Coast Africa, South America has seen a and the Gulf of Mexico, so there significant increase is a lot of potential traffic. It’s at a in thruster crossroads of all the main Atlantic overhauls “We have a symbiotic relationship has a very competitive offering.” trading routes. which means we can be flexible With this collective commitment “The next attribute is what we in handling our customers’ to secure Las Palmas’ place in global and Astican can offer owners within requirements. This year we’ve seen repair and overhaul capability, the the perimeter of the shipyard. The a real ramp-up in thruster exchange future is looking bright. fact we’re fully integrated, and and overhaul. In addition, Rolls-Royce The yard already has an benefit from the deep-water harbour is approved to carry out work in impressive range of facilities and waterfront location is ideal, Tenerife Port, giving flexibility across with seven docking lines and a especially for the larger rigs. the Canary Islands. Syncrolift, and next to come is a “Finally, the burgeoning maritime multi-million Euro investment in capability beyond the fence of the a new graving dock, large enough Fixed price offering pays off yard is a key strength. Las Palmas to handle vessels up to 320m long. has great infrastructure, an excellent This follows a recent investment in In 2017, Rolls-Royce carried supply chain and a highly skilled a new quayside facility to handle out several large overhauls, workforce, which are all essential for the growing demand for UUC typically exchanging six large the type of work we do. azimuth thruster overhauls. thrusters on a rig. To exchange “The Spanish Government is very Astican’s parent company also a set of six UUC thrusters for supportive of developing maritime owns the Astander yard near Bilbao ready-overhauled units, the capability on the island, and there’s in Spain. Together with Rolls-Royce, Rolls-Royce team can typically also a considerable number of it is considering repeating this model do this in 10 days. maritime studies available at the of success there to offer a fully The alternative, especially local university. Together with the integrated service to cater for the when rigs are quayside for abundance of specialised talent popularity of what Las Palmas longer periods, is to take off the available, it means that Las Palmas can offer. ● units and overhaul them in the workshop. Working in teams of four, trained service specialists can complete the job, including refitting, in 45 to 60 days. “One of the big attractions “One of the big attractions for customers is that, for our customers is the fact that together with Astican we together with Astican, can both offer fixed price for service and docking,” says we offer a fixed price for Nils-Reidar Olsvik Valle. “This service and docking, which takes away a lot of hassle for owners, and means they can take away a lot of hassle” deal direct with either us, or the yard, and get the same high-quality service.” Nils-Reidar Olsvik Valle
50 Rolls-Royce Indepth magazine rolls-royce.com
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