WÄRTSILÄ TECHNICAL JOURNAL
f o u r7. 02
Twenty 2017
ENERGY FUTURE 12 Reliable power supply 46 Working with robots for data centers The trial continues in Wärtsilä’s Modern gas-fired engines Central Distribution Centre in have an enormous potential the Netherlands
COVER STORY
THE FIRST INTEGRATED 42 HYBRID POWER page MODULE IN THE MARINE MARKET
MARINE MARINE 30 Taking control to 38 Cleaner power the next level for ships Multipurpose Wärtsilä SAMCon cold ironing container Electronic wastegate solution for cargo ships in detail issue no. 02.2017 WÄRTSILÄ TECHNICAL JOURNAL | WWW.WARTSILA.COM
Contents TOWARDS A SMARTER AND SAFER FUTURE
In late August this year, the offshore vessel Highland Chieftain ENERGY conducted a series of manoeuvres, off the North Sea coast of Decoding small-scale LNG supply contracts. . . . .4 Scotland. What made this voyage a milestone was that the vessel Expanding small-scale LNG was operated from 8000 kilometres away, in San Diego, with a combination of Dynamic Positioning (DP) and manual joystick with private-sector investment...... 8 control. Transforming data centers ...... 12 This development speaks volumes about autonomy finding its Powering isolated grids ...... 18 way into the marine industry. Maritime has always been a people’s Catching the ‘surge’...... 22 industry – there’s always a human in the loop. But it is important to note that autonomy doesn’t necessarily mean unmanned. All systems and functions are being built keeping people in mind, MARINE locally or remotely. Steering into a new future...... 24 Digitalisation and autonomous systems are changing complete Taking control to the next level...... 30 value chains, but they also help people make better decisions and The new Shuttle Tanker...... 34 reduce the number of errors. It can significantly improve safety in the marine industry, where about 90 per cent of the accidents Wärtsilä engineers offer ‘technical solutions’ are caused by human errors, often due to fatigue. To avoid tired for cold ironing...... 38 and disoriented crew, dull and repetitive tasks can be left to the Achieving full hybrid potential machines, while people can focus on making important decisions with the help of analytics and predictive technologies. At Wärtsilä, DECODING SMALL-SCALE LNG SUPPLY CONTRACTS by mastering synergies...... 42 we strive to make all our products and services user-centric. On land and at sea. LNG has all the potential to become easily FUTURE Our vision for Smart Marine ecosystem is to combine smart vessels available for everyone who wants it. Faster, easier, and safer together with robots. . . 46 with smart ports to enable more efficient use of resources. Remote operation capability is one concrete step in that journey. A case in point is our interesting story from Kampen, the Netherlands, where robots are helping make logistics faster and safer. The piece explains, in simple terms, how people and autonomous systems can work together to achieve great successes. This edition promises to bring you closer to our fast-changing realities at Wärtsilä, give you the latest technological updates in the iPad THIS ISSUE OF IN DETAIL is also available on iPad as a industry, and leave you with some food for thought. Wärtsilä iPublication app from Apple's Appstore, as well as in a browsable web version at www.twentyfour7magazine.com. Web Power to Wave Brand new Ilari Kallio Director, Digitalisation isolated grids power concept Wärtsilä Marine Solutions, Engines Publisher: Wärtsilä Corporation, John Stenbergin ranta 2, Combining internal WaveRoller, equipped with Shuttle Tanker offers a new P.O. Box 196, FIN-00531 Helsinki, Finland | Editor-in-Chief of In Detail combustion engines with an Wärtsilä’s components, is level of economical and Editor-in-Chief: Ilari Kallio | Managing editor and editorial office: Virva Äimälä | energy storage battery system one of the most promising ecological solutions by using Editorial team: Saara Eder-Falck, Marit Holmlund-Sund, has great potential for savings. wave energy devices. Wärtsilä’s systems. Dan Pettersson, Mirja-Maija Santala, Dinesh Subramaniam, Mikaela Terhi and Minna Timo l | Layout and production: Spoon | Printed: October 2017 by PunaMusta, Joensuu, Finland ISSN 1797-0032 | Copyright © 2017 Wärtsilä Corporation | Paper: cover LumiSilk 250g/m², inside pages UPM Fine 120 g/m² E-mail and feedback: [email protected] MORE ON PAGE 18 MORE ON PAGE 22 MORE ON PAGE 34
Cover illustration: Wärtsilä.
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Large-scale Small-scale
/ IN DETAIL ENERGY Supply situation (near future) Oversupply Few alternatives for buyers [
Contract duration Trend towards shorter contracts Medium-term contracts and spot trading
Pricing model Trend towards market-based pricing Indexed slightly below alternative fuels; or Cost+ from hub’s price
Payment and delivery obligations Take-or-pay for long-term and Take-or-pay Cargo-by-Cargo for spot trading
Impact of logistical and port costs Low-Medium High
Buyer’s pricing intelligence / experience High Low / none
Table 1 - Differences between large-scale and small-scale LNG.
With a new fuel comes the question: How largely been linked to crude oil or a basket Start date much is it reasonable to pay for it? Crude oil of oil products in Asia, they were initially Since there are not many alternative buyers is traded globally on a scale that leads to a linked to Brent oil in Europe, but are now and sellers for small-scale LNG, the delivery completely liquid market with transparent increasingly moving towards hub prices of LNG in accordance with the timetable of pricing. It is not difficult to contract heavy following the increased liquidity of the NBP the contract is crucial for both parties. But fuel oil (HFO) or light fuel oil (LFO) as (United Kingdom) and TTF (Netherlands) during this time, if either the buyer or the Decoding small-scale LNG there are benchmarks and multiple suppliers gas hubs. seller of LNG is constructing a new facility, available. It is also feasible to transport these In North America, gas markets are hub this could present a major risk. As LNG fuels fairly long distances. The picture is very based, with Henry Hub being the most sales agreements should be negotiated and supply contracts different for small-scale LNG. In many parts well-known. When prices diverge between signed before the construction of the facility, of the world, there is only one supplier or, in regions, arbitrage opportunities are created. assigning a realistic start date is of utmost the best-case scenario, a few. Furthermore, This means excess large-scale LNG will go to importance. There should be a funnel where the prices published for conventional, large- the region that is willing to pay the highest the start date of the contract is specified in AUTHOR: John Reinlund, Business Analyst, LNG Solutions, Wärtsilä Energy Solutions scale LNG deliveries have very little use for price. There is currently, and for several an increasingly tighter time range as the mail: [email protected] someone interested in contracting smaller years to come, an oversupply of LNG, which facility comes closer to commissioning. quantities. has improved the bargaining position of Schedule slip could have serious financial When the buyer has no or little buyers. This is leading to more variation in consequences. experience, the seller has the power in price indexation, more spot trading, shorter- negotiations. Therefore, this article aims to term contracts (previously 25-year contracts Logistics provide a few pointers to level the playing were common) and destination flexibility: In large-scale LNG, the trend is towards field. In order to understand the small- Free On Board (FOB) instead of Delivered increased destination flexibility. The buyers At an accelerating pace, the world is for others. Pipelines can only stretch so far, scale LNG contracts, one has to have some Ex-Ship (DES). want FOB contracts instead of DES, so transitioning from liquid hydrocarbons and LNG has previously only been available knowledge about how large-scale LNG is Large buyers hedge their LNG prices that they can divert cargoes to spot buyers to other fuels. While renewables are if consumption correlates with what a large contracted. by having a portfolio of contracts with in case they do not need them. This is increasing their market share, natural LNG carrier or a tanker truck can deliver. Unlike the crude oil market, the gas different suppliers and pricing mechanisms. not really applicable in the small-scale gas is not far behind. The use of pipeline But now, diversification is taking place to market cannot be considered a uniform This is a luxury small-scale buyers do not market, since LNG cannot be economically natural gas and liquefied natural gas (LNG) fill the market gap and, with time, LNG has international market, as regions are not have. If a small-scale buyer has only one transported very far on small-scale carriers has for a very long time been commonplace the potential to become easily available interconnected and trading is still fairly supply contract, there is less room for error. and there are few alternative customers. in some geographical markets and worldwide for every consumer who uncommon. Therefore, pricing mechanisms Therefore, there are some clauses in an LNG However, having the shipping component industries, albeit an unattainable dream wants it. have developed differently in different parts sales agreement which small-scale buyers in one’s own hands might save some money of the world. So while LNG prices have should pay extra attention to. for the buyer, but FOB contracts would also 4 in detail in detail 5 [ ENERGY / IN DETAIL ] WÄRTSILÄ TECHNICAL JOURNAL 02.2017
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require the buyer to assume responsibility Take-or-Pay work fairly well for national gas be that the price provides an acceptable / IN DETAIL ENERGY [ for ship charters, insurance, boil-off gas and grids and baseload electricity production, return on investment for its facilities and port costs. In some cases, DES contracts are but for power plants running peak loads, operates at a reasonable profit. The seller advantageous if the supplier can utilise the the buyer would like considerable flexibility wants the price to reflect the market value of same ship for other customers and share the when it comes to annual quantities. If the the gas, while the buyer wants an advantage costs. Those new to the market would be LNG supplier is the only source of fuel over competing fuels. Buyers also want the better off with a DES contract. But to shave (meaning there are no alternative suppliers price to mirror the price risk in the sales of off some hidden cost, considering FOB may and alternative fuels cannot be used), it is their products or services (e.g., electricity). be a good option. also important to specify what happens in In case of a new market with poor credit case of failure to deliver. ratings, the seller would also require a Contract length premium in order to cover the credit risk. The contract length is often determined Timing Prices are linked to different indices in by the financing needs of the parties The timing of negotiating an LNG sales different parts of the world, and generally as financial institutions require certain agreement also matters as these contracts small-scale LNG is influenced by large-scale guarantees. For a utility looking to build contain a price review mechanism with LNG. Most often in South-East Asia, prices an LNG terminal for its power plant, this the purpose of restoring the conditions of are linked to Brent crude oil, in Northern means a fuel supply contract that is back- when the agreement was signed. The base Europe to TTF hub prices and in the to-back with the length of the power period of an index is defined in the contract western hemisphere to Henry Hub. This is purchase agreement. But even without such and constitutes the reference period for understandable as LNG suppliers don’t want requirements, a medium-term contract the price. The base period values will to absorb the price risk of buying according might be preferred. The trend in large- affect future prices, so it is important not to one index and sell according to another. scale LNG is towards shorter contracts and to accept one that would result in a future But this is not necessarily in the interest spot deliveries, but in small-scale LNG one disadvantage. of the buyer. Ideally, a consumer wants wants to make sure that supply of fuel is A review period for determining the to make sure his fuel costs are lower than guaranteed for a longer time. However, if index to be applied is also specified. Instead the competitor’s. If the competitor is using one expects that the number of suppliers in of choosing a particular day as reference HFO or LFO, this is the preferred index. Fig. 1 - Discount on LNG FOB price compared with a reduction of LNG terminal CAPEX. the region will increase, it might be a good point for the index, an average over a longer For the buyer, it would be ideal if the price idea to have a shorter contract, so that a new time period is chosen. The intention of this would be linked to a local index, but as they contract can be negotiated when the buyer’s is to smoothen out peaks. The period is seldom have sufficient liquidity, the seller bargaining position is better. usually with a lag if time is needed in order probably insists on an international index. It to collect the data for calculating the index. is common to use Brent crude as an index, Annual Contract Quantities If the contract is increasingly which is beneficial since it is easy to hedge, One challenge with a long contract is disadvantageous to one of the parties but there is no guarantee that the price that the quantities required may change of the contract, it should be returned to of crude oil and refined products cannot considerably. Given the fact that a equilibrium. The contract should state a diverge in the future. also reduces the transparency of the pricing From the figure, it is apparent that even liquefaction facility wants to produce at price adjustment frequency. With a suitable Other, more experimental indexing can mechanism. By coincidence or not, the final a minor discount on the LNG price has a steady rate and there seldom are other frequency, the price is kept close to the be considered if the buyer, e.g., a dual-fuel price often ends up close to the cost of the the same impact as reducing CAPEX spent takers for a cargo, the seller wants to make market level. Buyers would ideally want to power plant, can use other fuels. Then a competing fuel. on the LNG terminal by several million sure that the buyer takes the cargoes that mirror the same price adjustment frequency different index can be chosen, e.g., Henry A few cents per MMBTU might sound USD. While spending less on the LNG have been assigned to him. Also, the buyer they have with their own customers. Hub or NBP, so that one can play with price trivial, but it has a substantial impact on terminal will result in lower performance, wants to be certain that his fuel needs can differences and produce using the fuel that the cost price of gas for the LNG terminal. reliability and perhaps safety, the properties be met. Therefore, the contract specifies an Pricing mechanism is currently most affordable. Such a strategy Figure 1 illustrates the significance of a of LNG will not change when lowering Annual Contract Quantity (ACQ). These The price of LNG is obviously one of the might, however, be difficult to align with the discount on the FOB LNG price compared the price. The savings also remain more or clauses generally allow for some downward most important points when negotiating an Annual Contract Quantities. with a reduction in total infrastructure less the same in both low and high price flexibility. The buyer has to pay for the LNG sales contract. With few suppliers to What can be seen in reality is that cost for a generic LNG terminal (including environments. Therefore, the LNG sales cargoes whether he takes them or not (Take- choose from and a low level of experience suppliers of small-scale LNG offer a hub or marine infrastructure) designed to supply contract should be given considerable or-Pay), but the outstanding cargoes should among buyers, it is often the suppliers that oil products index plus a fixed component. gas to a 50, 100 or 200 MW power plant deliberation and if needed, an experienced be taken the following year, in addition have the upper hand in deciding the terms. The fixed component comprises not only located at a distance of 300 and 600 nautical consultant should be brought in to support to the normal ACQ. Strict ACQs and The principles of a fair agreement should the logistical costs in a DES contract, but miles, respectively, from the LNG supplier. negotiations. 6 in detail in detail 7 [ ENERGY / IN DETAIL ] WÄRTSILÄ TECHNICAL JOURNAL 02.2017
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P LAT FOR M S U P PLY V E S SEL ( P S V) F LOAT I N G S TORAGE & ( REGAS I FICATI ON ) U N IT L E G E N D OF F S HORE SERVI CE ( F S R U / F S U ) VES SEL (OS V) W Ä R T S I L Ä O F F E R I N G
G A S L I N E
S H I P R O U T E O I L & G A S P L AT F O R M
P O W E R P L A N T L A R G E L IQUEFAC T ION P O W E R P L A N T L A R G E T E R M I N A L / IN DETAIL ENERGY P LANT
[ P O W E R P L A N T S M A L L L N G C A R R I E R
REL IQUEFAC T ION U NI T There is currently an abundance of LNG risks. At the present time, there is a distinct R E L I Q U E FA C T I O N U N I T REG A S I F ICATI ON L N G C A R R I E R UN IT available for large-scale applications, with lack of both small-scale LNG terminals and a
BU N KER I NG TER MI N AL new LNG supplies coming from Australia, dedicated small-scale LNG carrier fleet, with and increasingly also from the United States. few players willing to invest in both terminals L N G F U E L L ED PA S S ENG E R S HI P With the supply base growing, leading and vessels to support a relatively small LNG BI O GAS P O W E R P L A N T AND F L O A T I N G S T O R A G E A N D L IQUEFACTION market players, such as international oil delivery volume. L N G S T O R A G E R E G A S I F I C A T I O N B A R G E ( F S R B ) P L A NT P O W E R P L A N T SATE L L ITE AND BUNK E R I N G TERMI NAL majors and state-owned oil companies, are Secondly, while demand for small-scale
BUNK E R I NG expressing a growing interest in making LNG LNG is driven by power generation, power V E S S EL LBG F I L L ING S AT E L L I T E T E R M I N A L STATI ON available for small-scale applications, as well. utilities often lack the necessary expertise
P O W E R B A R G E The primary drivers for the growth of and resources – including labour, know-
SATEL LI TE TERMI NAL L N G F UEL L ED small-scale LNG market will be its use how and capital – to develop and implement CA R G O SHI P as shipping fuel, driven by the upcoming LNG projects. IMO 2020 regulations, which will limit The third major obstacle in the expansion MINI L IQUEFAC T ION P LANT B U N K E R I N G T E R M I N A L the sulphur in fuel oil used in ships to of small-scale LNG is the need to adapt the
SMA L L / MED IUM 0.50% m/m (mass by mass) from 1 January methodologies used for large-scale projects S MALL TE RMI NAL L IQUEFAC T ION P LANT J E T T Y L N G F I L L ING 2020; and its use as a less expensive, to the small-scale context. The methods that STATI ON more sustainable alternative to diesel for exist at present are often too complex and power generation in remote and island costly to be viable for small-scale plants. S M A L L L N G C A R R I E R locations. Although the industry is aware However, by developing new processes that that LNG has the potential to be more cost are leaner and less expensive, but still safe, the competitive than other alternatives, the small-scale LNG market has the potential to P O W E R P L A N T high up-front costs related to establishing be profitable for various applications. a small-scale LNG supply chain are still causing doubts. The power of BOOT A number of recent market developments A potential solution to the first and second support the growth of the small-scale challenges is a funding model known as LNG market. In South-East Asia, both BOOT (Build-Own-Operate-Transfer). Expanding small-scale LNG with the Singapore LNG and Tangguh Train 3 It is a form of project financing in terminals will soon be able to load small- which a private or, more often, public- private-sector investment scale LNG carriers, thereby expanding sector player, such as a government agency the options for small-scale LNG sourcing. or government-owned utility, awards a Meanwhile, the global LNG carrier fleet contract to a private organisation to develop, is gradually growing. There are currently finance, construct, own, and operate an AUTHOR: Saara Kujala, Manager Project Development for South-East Asia and Australia, Wärtsilä Energy Solutions some 25 small-scale LNG vessels with infrastructure project during a defined mail: [email protected] capacities of less than 40,000 cubic metres concession period. The fees collected during in operation, with eight more expected to be the operational period generate a return on commissioned in the next two years. investment for the concession holder. At the Despite these developments, the small- end of the concession period, the project is scale LNG market needs to solve three handed back to the concession counterparty. challenges for its potential to be realised. The BOOT model has been used since the Private sector participation through the help solve many of the energy challenges late 1980s to finance large infrastructure Build-Own-Operate-Transfer (BOOT) model of developing countries and remote, off- Three key challenges projects such as toll roads, railways and may hold the key to supporting the expansion the-grid locations, the lack of financing and The first challenge is the high up-front capital power plants. of the small-scale liquefied natural gas (LNG) infrastructure remains an obstacle to its cost of establishing a small-scale LNG supply The advantage for the public sector market. Although small-scale LNG could more widespread acceptance. chain, resulting in increased perceived project player is that, by awarding the concession 8 in detail in detail 9 [ ENERGY / IN DETAIL ] WÄRTSILÄ TECHNICAL JOURNAL 02.2017
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Utility electricity cost savings Payment per MWh security USD/MWh Package 140 LNG LNG carrier LNG SPA Gas Purchaser LNG vessel 120 supplier charter owner Equipment Shipbuilding
/ IN DETAIL ENERGY supplier & [ 100 agreement Sub - BOOT agreement Contractors Insurance 80 Shipyard
LNG terminal Fixed price EPC LNG terminal 60 EPC contract, owner Land & marine Contractor Completion permits, guarantee Land lease Host 40 Government Parent Equity, Guarantor Shareholders’ Loan 20 Agreement Agreement O&M contract Sponsors: Senior Operations & International and Lenders 0 maintenance local Investors 13,9 13,2 12,5 11,8 11,1 10,4 9,7 9,0 8,3 contractor Total LNG price USD/MMBtu (LHV) Owner’s Advisors Lenders’ advisors
The diagram above shows the electricity tariff reduction in USD/MWh for a power plant at different prices of LNG, in comparison to the diesel price. The break-even point for small-scale LNG feasibility depends on the delivered price of diesel and the price of LNG. As an example, if the delivered price of diesel is 520 USD/tonne, the price of delivered LNG should be below The above diagram presents a typical business structure with BOOT model, including project key 13.9 USD/MMBTu for generation with LNG to be feasible. If the base price of LNG was around agreements and counterparties. Successful project financing with BOOT model is based on a solid 6 USD/MMBTu, the all-in price of break-bulk transportation, storage and regasification should contractual structure and proper allocation of risks between the project parties. not exceed 7.9 USD/MMBTu to achieve savings in comparison to use of diesel.
Main assumptions: to a private company, it can attract private- small-scale LNG shipping and for terminals 2013, Wärtsilä has also expanded its mandate sector funds for projects, allowing the that allow project developers and owners to cover project development and equity Item Value public budget to be prioritised for other to implement small-scale LNG projects. investments into small-scale LNG terminals, projects. Moreover, it can attract technical, Moreover, Wärtsilä has the capability to with several LNG projects currently under Delivered price of diesel 520 USD/tonne project management, and operational and construct small-scale LNG terminals on a development in South America and South- LNG price slope (FOB basis) 11% of relevant crude oil price index maintenance expertise from the private turnkey EPC basis and operate and maintain East Asia. sector in areas where its own know-how them under long-term contracts. As a total LNG-solution provider, Crude oil price 50 USD/bbl may be lacking. For the private company, Wärtsilä also has experience in Wärtsilä has the advantage of being able Efficiency difference between 4% lower efficiency for diesel power plant (including combustion the contract length is designed to ensure implementing small-scale LNG projects to deliver the complete project scope: diesel and gas power plant efficiency difference, equipment ageing over life cycle and fuel losses) that investment costs can be recovered and a under BOOT arrangements. Wärtsilä’s from development and investment, to O&M cost difference 2 USD/MWh higher for diesel power plant profit can be made. project development and customer supplying the EPC for the small-scale LNG financing arm, Wärtsilä Development & terminal, and to ownership, operation and Wärtsilä’s role in small-scale LNG Financial Services Oy (WDFS), has been maintenance. In addition, through Wärtsilä’s Wärtsilä has a key part to play in the developing and investing equity into expertise in LNG carrier design, interface development of small-scale LNG markets as Independent Power Producer (IPP) power to LNG terminals can be optimised. Last it can help remove the three major challenges plants using Wärtsilä engine technology for but not the least, Wärtsilä has the capacity that the market is currently experiencing. the past 30 years. Its track record includes to bring all these aspects together to create As a total solutions provider, Wärtsilä the successful development, financial closing a total solution that is optimised from is the market leader in developing lean, and construction of more than 30 projects, the point of view of cost, efficiency and cost-effective technical solutions both for representing around 3.7 GW, globally. Since feasibility. 10 in detail in detail 11 [ ENERGY / IN DETAIL ] WÄRTSILÄ TECHNICAL JOURNAL 02.2017
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The phenomenal use of information facility become the primary source of power one needs to understand the functional technology has made data centers an supply? And can this be achieved using requirements of an emergency back-up Transforming data centers indispensable part of modern day business cleaner forms of energy? The answer to all system. They are: needs, as they store an enormous volume of of these is a big YES. Our white paper – Very rapid automatic start-up: Data data that is generated on a daily basis. Every Smart Power Generation for data centers centers use Uninterruptible Power Supply AUTHOR: Adam Rajewski, Manager, Data Center Technology, Wärtsilä Enery Solutions data center, thus, needs an extremely reliable – substantiates that the solution lies in (UPS) systems based on electrochemical mail: [email protected] and affordable power supply to ensure modern gas-fired engines. batteries. They are typically dimensioned uninterrupted functioning, 24/7. to last a couple of minutes and are very The traditional mode of power supply, The modern approach expensive. which involves a combination of grid The need for a smarter solution for Modularity of capacity: A good emergency Did you know large data centers gas-fired engines, holds the potential of electricity and diesel generators, has its own emergency power supply has led to the power supply system needs spare capacity consume power equivalent to the power providing affordable and reliable power drawbacks in the form of unstable power advent of modern gas-fired engines that are in a separate independent generator set, consumption of an average-sized town? and also generating additional profits. prices and high local emissions. cleaner than diesel engines and work faster. sufficient to cover the capacity lost due to But a solution, in the form of modern But what if these emergency power To understand how gas-fired engines maintenance or isolated failure. generation facilities helped in revenue are changing the dynamics of emergency Ability to run on locally stored fuel: generation? Can a back-up power supply power back-up mechanism for data centers, The facility needs some locally stored 12 in detail in detail 13 [ ENERGY / IN DETAIL ] WÄRTSILÄ TECHNICAL JOURNAL 02.2017
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Fig. 2 - MS Viking Grace, a cruise ferry powered by liquefied natural gas, has been safely carrying passengers since January 2013.
fuel to ensure an uninterrupted supply Gas engines, come of age matter of fact, small-scale LNG storage and for a certain amount of time until the But not long ago, gas-fired engines suffered regasification plants are so reliable and safe external power supply can be restored. a major drawback in terms of very delayed that they are currently being installed on Technological maturity: Finally, the start-up timing – at times as high as 10 passenger ships. (Figure 2) requirement of maturity is natural minutes. But recent years have seen huge Clearly, modern gas engines hold enough for a system where reliability is of progress on this front. Now these state- power to become a potent alternative to fundamental importance. of-the-art gas engines can be started and diesel generators. However, gas engines brought to full power in considerably less go far beyond merely providing an An internal combustion engine still remains than one minute of the starting order, equivalent solution. Restricting carbon to be the only solution capable of meeting the ushering them into the world of emergency emissions is very important amid growing above mentioned functional requirements. power supply. environmental concerns. And adopting gas But such an engine does not have to run on In Figure 1, there are some exemplary and engines is the need of the hour as natural diesel fuel anymore – especially, when there representative start-up sequences obtained gas is the cleanest of all fossil fuels. Using
is a cleaner and more economically effective during actual engine tests performed by gas means less CO2, which in turn means alternative: natural gas. Compared with other Wärtsilä. corporations can reduce their carbon fuel-based technologies used in large-scale Gas engines have also taken care of the footprint besides reducing costs. (Figure 3) Fig. 1 - Start-up curves of a modern medium-speed gas engine. These are direct screenshots from engine control systems and were made commercial power industry, gas engines issue of fuel storage. Recent years have This means operating the generating sets during tests of a rapid start-up of a medium-speed gas engine operating in island mode. The top diagram shows a case of linear loading, while the bottom one involved pre-programmed load steps. In both cases start-up duration (40 and 41 seconds respectively) is measured from the meet all the features of a smart power backup seen emergence of small-scale affordable continuously instead of relying on electricity start command until full output. Testing was performed in island mode. system. It is fast to start, cheap to build, and gas storage technologies, especially in the grids would have a positive effect on the extremely flexible. form of liquefied natural gas (LNG). As a carbon footprint of the data center. 14 in detail in detail 15 [ ENERGY / IN DETAIL ] WÄRTSILÄ TECHNICAL JOURNAL 02.2017
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CARBON FOOTPRINT MAY BE FURTHER REDUCED BY USING WASTE HEAT!
Fig. 3 - Carbon footprint of different sources of electricity. Note that generating power with on-site natural gas power plant has lower footprint than the grid electricity. Fig. 4 - The self-generation model for a gas-fired data center power plant.
IPP or data center operator Regional electricity 1 builds a gas engine power market The real power footprint, then it may very well be used as a any disruptions in the grid power supply, plant at the data center site That modern gas engines are the future of primary source of power. it would automatically switch to the emergency power back up systems, has been This would make the local power plant emergency power supply mode. This might established beyond doubt. But gas engines the primary source of electricity, while the be a preferred approach for markets with Data center owner and IPP are not merely futuristic alternatives to grid functions as a backup. This approach high electricity cost. (Figure 5) 2 sign an emergency supply Electricity for Electricity and AS diesel generators. In fact, gas engines are protects the data center operator from With the phenomenal advancement in gas contract Data center to the market the game changers – because they can go higher power costs and reduces carbon engine technology and the advent of LNG beyond emergency. footprints too. solutions, there is no denying that the future Once an emergency power generation Data center operators can generate of gas-fired engines, in data centers, holds Data center purchases system is built using a solution that is additional revenue as data centers do not immense potential. 3 electricity for data center neither legally nor technically restricted operate on full design load. That time can be from the electricity market from operating beyond emergencies, used to generate additional power & sell it there are two essential ways of using this to the electricity market along with the spare IPP operates the power plant capability: and redundant capacity of power plant. Contract Self-generation (Figure 4) on a merchant basis, selling 4 Emergency power Merchant operation electricity and system Merchant plant concept services to the market Power Plant Self-generation model Unlike the self-generation model, in this Data center (Owned by third party) This model shifts the source of primary case the gas-fired power plant can be used Site Fence power from the electricity grid to the only as an emergency back-up power emergency power generation facility. If a source while operating independently as data center has a power-generation facility a merchant generating station co-existing Fig. 5 - Merchant plant model for the gas-fired data center power plant. that can be operated continuously on an with data center and selling its production inexpensive fuel with very low emission to external customers. In the event of 16 in detail in detail 17 [ ENERGY / IN DETAIL ] WÄRTSILÄ TECHNICAL JOURNAL 02.2017
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Total Electricity Demand [MW]Total electricity demand (MW)
40
35 / IN DETAIL ENERGY [ 30
25
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Fig. 1 - Load demand without solar generation. Powering isolated grids The authors of this paper studied the added Providing spinning reserve 30-minute resolution value a Wärtsilä hybrid power plant (with The integrated energy storage system The demand profile has a 30-minute internal combustion engines and energy comprises Li-Ion batteries with peak resolution and the load profile for this time AUTHORS: Hans-Alexander Öst, Manager, Business Development, Wärtsilä Energy Solutions storage) can provide its owners and operators power of 10 MW and 2.5 MWh of energy. period is presented in Figure 1. As the grid is Jyrki Leino, Senior Power System Analyst, Wärtsilä Energy Solutions in terms of economical savings and enhanced The energy storage size was selected to be an isolated grid, i.e., microgrid, the demand Mats Östman, Senior Development Manager, Wärtsilä Energy Solutions performance. The case study and simulations slightly bigger than the generating unit’s profile equals the load that the generating mail: [email protected], [email protected], [email protected] were made based on actual load data from an size, thus having sufficient capacity to units have to produce. In Figure 2, the same islanded industrial operation. provide the spinning reserve capacity equal demand data is presented, but here also The hybrid power plant in question to one unit at full load. In the case of a solar PV generation with a performance comprises six Wärtsilä 20V34DF dual- generating unit trip, the energy storage has ratio of 30% of total demand has been fuel (DF) engines, capable of running on the capacity to provide power for 15 minutes, included. Fast-starting internal combustion engines natural gas, light fuel oil and heavy fuel oil, which is more than enough time to start one When evaluating the demand profile, the – integrated with an energy storage providing the plant extremely valuable fuel of the standby units and take over the load. power need is relatively stable with a load battery system – provide great potential flexibility. The Wärtsilä 20V34DF engine Therefore, the energy storage can replace slightly above 35 MW. It can also be noted for fuel and cost savings, especially in delivers nearly 10 MW each with a total the spinning reserve capacity from one from the profile that there are eight major isolated grids. plant output of 58 MW. With the energy generation unit. In case there is solar PV events where the load is dropping rapidly storage available in the system, the total generation in the micro grid, there will be with nearly 20 MW. hybrid plant capacity is 68 MW; and if additional spinning reserve requirements The trips in the system are causing solar photovoltaic (PV) generation with a from the solar PV due to intermittent additional stress on the generating units. performance ratio of 11 MW would be added nature of solar generation. Hence with the However, it is also important to note that to the system, the maximum generation selected approach, the presence of solar PV demand data with second resolution would capacity would be 79 MW. will increase the need for spinning reserve be required to be able to study the real As the case study is in an isolated grid, capacity. impact on, for example, frequency of these there are requirements on the generating The demand data of the industrial load drops. assets to have spinning reserve capacity. For site including solar PV generation was The Wärtsilä DF engines can ramp to full the generation units, it was selected to have simulated with the plant dispatch modelling load in 60 seconds and are capable of taking contingency reserve equal to the generating tool PLEXOS®, a tool commonly used by single load steps of 30%, giving it sufficient unit operating at highest load and in addition utilities, consultants, system operators and fast and flexible generating capacity to also 80% of the actual solar PV generation. regulators globally. respond to these load changes. 18 in detail in detail 19 [ ENERGY / IN DETAIL ] WÄRTSILÄ TECHNICAL JOURNAL 02.2017
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Generation Mix [MW]Generation mix (MW) IRR [%IRR] (%) a andnd NPV N (MUSD)PV [M$]
40,00 12 120% 35,00 10 100% 30,00 8 80% 25,00 / IN DETAIL ENERGY MUSD [ 20,00 6 60% 15,00 4 40% 10,00 2 20% 5,00 0,00 0 30 $/MWh 30 $/MWh 40 $/MWh 40 $/MWh 50 $/MWh 50 $/MWh 0% Solar 0% Solar 30% Solar 0% Solar 30% Solar 0% Solar 30% 01.01 01.01 02.01 03.01 04.01 04.01 05.01 06.01 07.01 08.01 08.01 09.01 10.01 11.01 12.01 12.01 13.01 14.01 15.01 16.01 16.01 17.01 18.01 19.01 20.01 20.01 21.01 22.01 23.01 23.01 24.01 25.01 26.01 27.01 27.01 28.01 Net present value [M$] 5,2 5,4 7,8 7,9 10,3 10,4 Thermal Generation Solar PV Internal Rate Of Return (IRR) [%] 65% 66% 88% 89% 111% 112%
Fig. 2 - Generation mix including thermal units and solar PV production. Fig. 4 - IRR (%) and NPV (MUSD).
Strong feasibility investment decisions. Especially in remote energy storage, and solar PV systems, which Energy storage annual savings (MUSD) Energy Storage Annual Savings [M$] The feasibility of energy storage, particularly locations, the potential enhancement that will improve its performance. (Figure 4) for industrial usage in isolated grids, as an can be reached by integrating energy storage The demand for ‘greener’ electricity integrated hybrid power plant is solid. In to the power plant are directly linked to the production keeps rising, and this is normally 3 10% this study, the energy storage was only used fuel prices and thus have potential to save achieved by adding renewable generation 2,5 9% as contingency reserve, i.e., to free spinning millions on annual basis. For instance, in to the system. However, as renewable 8% reserve capacity from the generating units. remote mines, factories and islands, where generation depends on actual wind speed or 2 However, in industrial use, the energy fuel prices are generally high, there is great solar irradiation, flexible generation assets 7% storage could as well be used for other potential of fully integrated and optimised are a must to be able to balance the network. MUSD 1,5 6% applications. The energy storage can e.g., hybrid power plants combining internal Hence, by optimising the thermal power act as a peaking unit and take on load steps combustion engines, solar PV and energy plant with energy storage, the complete 1 5% from the isolated grid, momentarily. storage. system can be operated at higher efficiency, 4% 0,5 The energy storage could also smoothen and by this also the total amount of emissions 3% load fluctuations, and if stable power is Hybrid opportunity can be reduced as less fuel is consumed 0 required the energy storage could be used With the available energy storage with same amount of energy, thus providing 30 $/MWh 30 $/MWh 40 $/MWh 40 $/MWh 50 $/MWh 50 $/MWh 2% for power quality purposes to stabilise technology and the decreasing prices of optimised system with ‘greener electricity’. Solar 0% Solar 30% Solar 0% Solar 30% Solar 0% Solar 30% the isolated grid and hence ensure the the Li-Ion batteries, the authors argue that In the study, fuel savings of 7% and annual Annual operational savings [M$] 1,9 1,9 2,3 2,4 2,8 2,8 production process for the industrial plant, hybrid power plants with energy storage savings of 8% were reached by adding only Annual operational savings % 7% 8% 7% 7% 7% 7% eliminating production losses for the plant. will come strong into the future power energy storage. For the multi-hybrid power Fuel savings [%] 6% 7% 6% 7% 6% 7% (Figure 3) generation markets. The possibilities plant, the operational savings were as high What already can be seen today is that to optimise the power generation by as 13%. Hence, there is a clear case also to there are solid financial grounds for investing developing hybrid power plants are integrate renewable generation to thermal Fig. 3 - Energy storage annual savings (MUSD). in hybrid power plants with integrated increasing all the time; already today it is generating systems. Also, all the generating internal combustion engines + energy apparent in, e.g., Europe and the USA that assets shall be sized and optimised taking storage. For the energy storage, the internal there are genuine interests for hybrid power into account how the complete system rate of return (IRR) in the most feasible plants with internal combustion engines and works with the actual or forecasted load case was 112% and net present value (NPV) energy storage, integrated and optimised profile. By integrating all generating assets 10 MUSD. In all analysed cases, positive with an energy management system. with an energy management system, the NPV’s and IRR’s over 30% were reached, It should also be noted that existing full potential of the complete system can be hence there are no doubts about favourable power plants can be enhanced by integrating unleashed. 20 in detail in detail 21 [ ENERGY / IN DETAIL ] WÄRTSILÄ TECHNICAL JOURNAL 02.2017
] ] “AW Energy have come up with a fantastic facility in Slough, outside London, it did not person that knows.” Wärtsilä partners with invention, which has been proven to work take long to find ways that Wärtsilä could Creak is similarly conscious of the AW-Energy adding wave at sea, but the information they are able improve the WaveRoller product. challenges that come with working with a power generation to its to extract on the longevity of the bearings “I think AW Energy had limited in-house much smaller company. capabilities as energy and seals is from simulated exercises,” resources and expertise available,” recalls “We are very aware that we’re a very, very system integrator. Creak explains. “What we’re giving them Creak. “They certainly understood about the big company and they’re a very, very small is a balance of mature technology in the bearing and what they wanted the bearing company. That can create some challenges in equation – so they’re able to use the past to do, but they had limited understanding communications,” he says. performance figures to a degree.” of what the performance limitations and The other issue is financial. The value of / IN DETAIL ENERGY / IN DETAIL FUTURE [ [ Even if the core technology is new, both requirements could be on their seal.” the equipment sold to AW Energy for its investors in AW Energy and the company’s Wärtsilä consulted on the overall seal and maiden project provides very little immediate potential customers will gain assurance bearing arrangement and recommended a return for the time Creak’s team has spent. from the fact that key components have transition towards a totally water lubricated “We would be disingenuous to say that it’s been used for decades, and come from a solution. This simplified the application a major contribution to our annual turnover reliable supplier such as Wärtsilä. and at the same time addressed another and profitability. However, we make these “They’re able to use the past performance environmental concern. investments because there’s a potential,” says figures to a degree,” Creak says. “Derivatives “There are studies and papers out there Creak. of the seal and bearing technology have that look at the portfolio of seal offerings If WaveRoller is successful and deployed been operating in other applications for over in the market and the general consensus, around the world, it has the potential to be one 50 years. This gives a sense of security and specifically in tidal applications, is that a of the most popular devices for power utilities. reliability.” mechanical face seal is the go-to choice,” “It’s a really big opportunity for them Ridgewell, who spent 17 years working for Thompson says. “But those don’t respond at the end of the day,” Ridgewell argues. Lloyd’s Register, says WaveRoller has tapped well in high-duty reciprocating motions.” “When this industry really takes off, which it established, respected suppliers for other Wärtsilä also decided to invest more time will, we’re talking tens of thousands of units. Catching the ‘surge’ parts as well. into supplying the WaveRoller by developing a And for every WaveRoller, you need two “We try to take as much off-the-shelf structural composite housing for the lip seals at bearings, so we’re talking about a very large technology as possible to limit the risk. its in-house composite manufacturing facility business opportunity.” AUTHOR: Richard Orange There’s lots of new stuff in there already.” in Slough. This will reduce the weight of the With AW Energy, the opportunity Wärtsilä’s seals and bearings business, device, making it easier to install and service. is considerably greater, but so is the based in Havant, UK, has unrivalled The other attraction for AW Energy is competition, with more than 200 devices experience supplying seals to the emerging Wärtsilä’s Services Division. Ridgewell is under development. wave and tidal energy industry. aware that operation and maintenance is key But Wärtsilä believes AW Energy, which Capturing the power of the waves is a bearing housings, composite bearings, lip of a short grid connection, while being fixed When the Marine Current Turbine to the WaveRoller’s cost-effectiveness and is the first device to receive a technology complex task, as the sea is constantly seal housings, and hydraulic couplings. to the seabed, under the surface, means device was pulled out of Strangford Lough appeal to utilities. It has ballast tanks that certification from Lloyds Register and to changing. One of the most promising The equipment is being fitted this summer the device is not as exposed to extreme at the start of 2016, it had produced most allow it to float back to the surface for easy be certified against DNVGL standards, is wave energy devices is WaveRoller, a before the device is shipped to Peniche, waves as most rival devices. For power of the world’s tidal energy. So Wärtsilä, by servicing, limiting the need for expensive among the most promising. submerged panel equipped with Wärtsilä’s Portugal, for a year’s trial operation in utilities the more even generation and easier extension, had at that point sealed 90 per and dangerous diving operations. “There are a lot of players out there, but components. the early autumn. In September Wärtsilä maintenance WaveRoller promises bring cent of the world’s tidal power produced. it doesn’t take a lot of time and investment announced it will partner with AW-Energy clear advantages over rival devices. “We had experience, and still have to The ‘glocal’ touch to work out the likely winners,” Creak says. When the British naval architect Chris adding wave power generation to its this day, we believe, that no other seal Having a global supplier such as Wärtsilä “And then we would typically offer our Ridgewell visited Wärtsilä’s Vaasa offices capabilities as energy system integrator. The wave forward manufacturer has,” says consultant engineer manufacturing key parts means that when services to the ones that we perceive have at the start of the project to develop the WaveRoller is unusual among wave Wärtsilä’s parts are essential to the device’s Simon Thompson, one of Creak’s team the device is rolled out globally, it will be the greatest chance of success.” first LNG-fuelled passenger ship at Turku energy devices, because it generates energy durability as they withstand rough weather members. easy for utilities to service and replace these The double certification, together with shipyard, as a surveyor for Lloyd’s Register, from the ‘surge’, the back-and-forth motion and require minimal servicing. parts wherever they are located. reliable, time-tested components, and the he saw first-hand how adept Wärtsilä can be waves make when they travel from the “The majority of the year, the waves are Striking the right balance “If you look at the service centres and knowledge that service engineers are nearby, with developing technologies. deep ocean to shallower waters. It has the quite small: one to two metres,” Ridgewell But AW Energy was drawn to Wärtsilä for representative offices of Wärtsilä and then will help utility customers convince their So after he returned to Finland to become potential to be one of the most popular explains. “And that’s why the bearings the company’s expertise as well as for its you place on that a global map of the world own financial backers and project insurers Chief Technology Officer for the wave energy devices for power utility customers. are so important: they allow the panel to equipment. wave resources, they pretty much match,” that the risks have been as much as possible start-up AW Energy, he knew where to turn. The device consists of a steel panel, which move in small wave heights. Because we’re “When you look at a technology there are Ridgewell points out. contained, making it easier to get the first “LNG has now really taken off and is fixed to the seabed, near the shore, at a structurally efficient, we’re very responsive a lot of rules and standards that people use. But there are challenges as well as benefits projects off the ground. Wärtsilä is a main player,” he says. “They’ve water depth of about eight to 20 metres. to the waves.” However, there’s a lot of conservatism in that, for a small start-up in working with a It seems to be working. AW Energy has a built it from a new technology to an The back and forth movement drives Ridgewell approached Wärtsilä. The and it’s really unravelling that conservatism,” company of Wärtsilä’s scale, particularly in pipeline of commercial projects and active established industry. Now we are at the same a closed hydraulic circuit, which in turn request filtered down to Les Creak, Wärtsilä’s says Ridgewell. “With renewable energy, you navigating through Wärtsilä’s many divisions. business development in six countries on point in the development cycle, and Wärtsilä drives a generator. An energy storage system Business Development Manager for Hydro, cannot justify having a lot of the costs.” “There’s a lot of expertise, but it is finding four continents. And when WaveRoller ends again is involved in that transformation.” then turns the pulsating output into smooth, largely because his team had worked When Simon Thompson, Kerry Jones the expertise that’s the challenge,” says its trial on Portugal’s Atlantic coast in late Wärtsilä has supplied AW Energy’s grid-compliant electricity. extensively with other developers and start- and Ross Strickland first met Ridgewell at Ridgewell. “You need to find that person 2018, AW Energy’s device will be one step first full-scale WaveRoller with metallic Being near the shore brings the advantage ups in Ocean Energy over the past decade. Wärtsilä’s in-house composite manufacturing who has sufficient contacts to find the closer to the market. 22 in detail in detail 23 [ MARINE / IN DETAIL ] WÄRTSILÄ TECHNICAL JOURNAL 02.2017
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Steering into a new future Tugs are sturdy powerful vessels capable hand availability of maximum power when Choosing the propeller of delivering the highest performance in in ship-assist operation. This makes the configuration (CP or FP) AUTHOR: Edgar Snelders, General Manager, Product Platform Thrusters assisting, towing or repositioning a vessel. solution relevant for tugboats, and other So what is the difference in performance mail: [email protected] This performance is commonly measured vessel types requiring thrusters. between CP and FP propellers? The in tonnes of bollard pull (BP) or the towing Design plays a vital role in making the hydrodynamic efficiency of an FP will be power and is obtained by the effective thruster configuration relevant to a wide the highest, but the difference between an performance of the propulsion components variety of vessels. Take for instance, the FP and a CP propeller is less than 2%. The The family of Wärtsilä Steerable system integration. So what are the and their integration. The newly developed hydrodynamic design of the series. It allows choice for a certain propeller configuration Thrusters (WST) have introduced a advantages for owners, operators and WST thruster series is versatile and can propellers to efficiently transfer all engine depends, primarily, on the needs of the new wave of solutions for the tugboat yards, what are the hallmarks of Wärtsilä’s be tailored to comply with specific vessel power into the water and convert it into application. business. The new design is marked by robust maintenance strategy, and how requirements, without compromising a thrust force without compromising on A CP propeller is a good choice over an outstanding propulsive performance, compliant is the new design to the on safety, performance, cost, simplicity, cavitation, noise and vibrations. For the FP propeller if both free sailing performance manoeuvring capability, reliability, stringent requirements on environmental reliability or efficiency. Designed for WST series, computational fluid dynamics and bollard pull are important. In this high overall efficiency, and advanced performance? integration with any electric motor, diesel, (CFD) analyses have been extensively case the difference in efficiency will be dual-fuel or gas engine in the speed range used to align the design of the propeller, compensated, for, by operational gains. 720-1800 rev/min, this series covers a power the thruster housing, the nozzle, and its Designers or shipyards can select a range of 800-3200 KW in eight different connections with the housing to achieve thruster with a CP propeller for vessels sizes. Wärtsilä also delivers a hybrid optimum hydrodynamic performance. with power take-off (PTO) driven fire- propulsion package with Wärtsilä engines, In the development of the new WST fighting (fi-fi) pumps. A CP propeller allows electrical and automation equipment, power series, detailed analyses were also made to the fi-fi pump to be operated at nominal management system and thrusters for 40-80 determine the hydrodynamic performance engine speed, while maintaining full vessel tonne BP tugs. This hybrid system allows of thrusters with ducted controllable pitch manoeuvrability. A thruster with a CP on the one hand emission free propulsion (CP) propellers compared to ducted fixed propeller provides a cost effective alternative when in ‘green mode’ and on the other pitch (FP) propellers. to an FP propeller with a heavy duty slipping 24 in detail in detail 25 [ MARINE / IN DETAIL ] WÄRTSILÄ TECHNICAL JOURNAL 02.2017
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The ProTouch system with its levers, touchscreen displays and indicators.
automation platform. The Local Machinery Vessel integration operational conditions, loads, temperature Control System (LMCS) contains redundant Tugs are extremely compact and agile expansion, bearing preloads and clearances. embedded controllers and a full colour vessels, where the equipment installed By means of loaded tooth contact analysis a Human Machine Interface (HMI) 7” onboard should occupy minimum space. good initial contact position is determined, Wärtsilä Steerable Thruster with PTO for diesel-mechanical drive. touchscreen at the cabinet door. The Thanks to compact and advanced system leading to a well-centred, full torque contact HMI’s user friendly graphical interface integration, thrusters have remained small, even in the most severe loading conditions. supports local control of steering and thereby reducing the need for additional This systematic approach leads to lower thrust, calibration and test modes, as well space in the machine room. There is no tooth stresses and thus increased reliability. as trending and logging, since the thruster’s need to install a separate header tank, nor With selected bearings, the WST series has a clutch integrated in the driveline, needed to The power of a nozzle 40% of the propeller diameter, and sensors and transmitters are connected to fit any separate hydraulic system. It is a one single maximum rating, allowing up to 8000 provide similar fi-fi functionality. Next in line is the variation in nozzles. A effectively contributes thrust up to the the LMCS. package installation, where the thrusters can running hours per year with a standard FP propellers feature in certain types of nozzle maximises the thrust at lower vessel speed of 16 knots by reducing ship’s water Smart instrumentation set-up and be installed from either below, above, or split mission profile. thrusters (WST-11 and WST-14) that have speeds and is hence a key element. Steerable resistance or drag. fieldbus technology have significantly mounting. To accommodate different vessel been designed to comply with Ice Class thrusters are used for bollard pull or free The choice of nozzle depends on the reduced installation and commissioning dimensions there are two propeller arm Integrated clutch requirements - Russian and Russian river sailing for which two different nozzles have vessel’s operational profile. In general, the times. The LMCS can communicate with lengths (PAL) available for each thruster size, The WST series for diesel-mechanic drives ice classes (RMRS up to Ice 3 and RRR up been developed. The bollard pull nozzle has bollard pull nozzle is more applicable to tugs an external remote control system through a short and a long variant. is standardly equipped with an integrated to Ice 40) as well as the Baltic Ice Class 1C. a length of 0.5 of the propeller diameter (L/ and workboats while the free-sailing nozzle is fieldbus and with the Wärtsilä ProTouch medium duty wet clutch. The clutch itself Larger WST sizes with FP propellers fulfil D=0.5) and a specifically designed exit area. more suitable for vessels operating in transit System to remotely control the thruster Drive train was specifically developed for the WST the requirements of Baltic Ice Class 1B. It is most effective at low ship speeds, while conditions, like platform supply vessels from the bridge and engine control room. Additionally, the drive-train of the thrusters thrusters along with one of the main clutch Propeller diameters range from 1.6m up also allowing efficient sailing at speeds of (PSVs) and inland waterway cargo vessels. With its slick levers, touchscreen displays is designed based on experience from the suppliers, and offers either on/off or slipping to 3.2m, and for each size a minimum of two 12–14 knots. and indicators, the contemporary ProTouch field and latest insights in gear and bearing execution thus enabling optimal operation propeller diameters is available, covering For free sailing applications, a dedicated Taking control system can easily be fitted into even the design. The gear teeth flank topology of the of the engine and thruster under all most of the needs of vessel installations in nozzle design has been developed, which Additionally, Wärtsilä’s next-gen thrusters most compact bridge designs, while WST-series is optimized by compensating conditions. The clutch suits both a CPP and this market sector. has improved performance. It is shorter, also come with a new machinery control providing the user with full manual control. for gear misalignments caused by FPP thruster application. The continuous 26 in detail in detail 27 [ MARINE / IN DETAIL ] WÄRTSILÄ TECHNICAL JOURNAL 02.2017
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The thrusters can be installed from either below, above, or split mounting.
to demonstrate its performance and vessels with thrusters from the WST series that answer the who, what, when, and how reliability - the torque transfer during are currently being built. The first vessel to of getting it right. synchronisation, clutch oil temperatures in be delivered is a 55 tonne BP eco-tug for For starters, there’s a clear distinction continuous slipping mode, and the ability to Dubai Dry Docks World. It’s equipped with of maintenance levels – from tasks that slipping mode allows a vessel with an FPP planetary gear boxes. The standard steering a basic seal monitoring functionality for the cope with torque variations. two WST-18 CP thrusters driven by Wärtsilä can be executed by the vessel crew to tasks application to operate at slow sailing speeds, system of the WST series is a hydraulic vessel crew. Ingress of sea water or oil leakage As part of the design assurance process, 9L20DF dual-fuel engines and a Wärtsilä that need to be executed at, preferably, a in the range of 0-50 per cent of the nominal closed-loop one. Alternatively, Wärtsilä can be monitored through visual inspection of more dedicated system validation tests were LNGPac. A series of 79m PSVs for Nam Wärtsilä service station. Then each thruster diesel engine rev/min. has also developed an electric steering the separate seal monitoring tank level. designed and executed alongside the full Cheong International Ltd is equipped with is accompanied by a specific maintenance system which is more energy efficient, scale thruster tests. The electric steering WST-18 FP units with electric steering in a schedule describing all tasks to be performed. Stroke of flexibility holds fewer components and has hardly Tested to perfection system passed the test with distinction by diesel-electric (DE) propulsion layout. The Next are the work cards detailing the Given that agility and manoeuvrability any wear parts (no pump, filters, valves or The journey, so far, has included numerous executing all pre-set steering actions against third reference is for a research vessel for step-by-step actions and required parts, are key for tugs, the steering system of the seals). The electric steering system provides performance and validation tests. Various pre-defined loads without overheating. The the Guangzhou Marine Geological Survey tools, consumables, and duration, as well WST series thrusters is capable of rotating equal or even greater performance levels for prototypes were tested on a full scale test rig system was also able to accurately position Bureau. The geological exploration vessel is as inspection criteria and limits. Lastly, the the thruster 360 degrees in both directions. positioning accuracy and system loads. to validate its performance under controlled the thruster at any azimuth angle and equipped with two WST-21 FP units as part measurement records give the customer With a maximum speed of 2.5 rev/min the conditions. Those with different dynamic without overshoot. Torque synchronicity of a DE propulsion system. an opportunity to record trends in the thruster can be fully reversed in 12 seconds. Environmental performance loading cases and multiple endurance runs between the two electric steering motors performance of an installation. Based on The steering system can bring the thruster That’s not all. Today’s environmental under maximum load and even overload was proven by comparing the individual A robust maintenance framework the maintenance schedule and work cards, back to neutral position from any allowable performance requirements set additional were tested. An advanced measurement current consumption of each motor. There’s more to the offering though. The Propulsion Services can support customers angle at any propeller and vessel speed. requirements for the lubrication system and system with a grid of over 140 sensors, In short, the new thruster series discerning marine market of today seeks with a lifecycle calculation tool which can Besides, it has the ability to hold the thruster components. outside and inside the thruster, recorded the successfully navigated the rigorous tests and insight into long term operational costs even be used to pre-determine the overhaul and in a fixed position under all conditions. The propeller shaft and steering seal exact test conditions and thruster behaviour. real time conditions with its versatile, cost- before purchasing the equipment for new- maintenance cost for a specific operating The steering system consists of two package form a barrier system between oil and The slipping clutch was given specific effective, powerful and environmentally builds, which has been the driving force period. steering units with pinions that drive one sea water. As a standard WST design, both attention amongst other validation efficient features. behind a robust maintenance strategy by With all its ducks in a row, Wärtsilä is common slewing gear via three-stage barrier systems are connected, and provide objectives. Three main issues were verified The results are for all to see. Several Wärtsilä comprising the four main pillars steering into a new, exciting future. 28 in detail in detail 29 [ MARINE / IN DETAIL ] WÄRTSILÄ TECHNICAL JOURNAL 02.2017
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Electronic wastegate with insulation.
Taking control to the next level Electronic wastegate without insulation.
AUTHORS: Marko Huhmarsalo, Senior Product Manager, Small & Medium Bore Engines, Wärtsilä Services Kaj Lundin, Senior Engine Expert, Turbocharging, Wärtsilä Marine Solutions mail: [email protected], [email protected] As of mid-June 2017, the multipurpose associated properties – engine reliability, co-operation between Wärtsilä and the valve Wärtsilä Electronic wastegate, developed stability, diagnostics and simplicity – supplier. The project aimed to develop a by Wärtsilä, is now offered as an optional were developed by Wärtsilä for these new wastegate valve package that could be used retrofit package – starting with the engines, and simultaneously the technology on new engine platforms and would also Wärtsilä 34SG range – regardless of power refined as a retrofit for older Wärtsilä 34SG be suitable for retrofit purposes for current Offered as a standard feature on all new application, and operational profile. engines because it had the same benefits of portfolio and field engines. Wärtsilä 31, Wärtsilä 46DF, Wärtsilä The exhaust wastegate valve is used to improved performance and reliability, and The validation of the new product 20V34SG and Wärtsilä 18V50SG engines, adjust the amount of exhaust gases passing offered improved diagnostics as well. This required a vast number of various rig and the performance-enhancing Wärtsilä through the turbocharger turbine, thereby is an example of Wärtsilä’s innovativeness on-engine laboratory tests performed by Electronic wastegate is now also available adjusting the turbocharger speed and the and how the latest technology benefits both both the valve supplier and Wärtsilä on as a retrofit starting with Wärtsilä 34SG charge air pressure. Accurate and fast control customers buying a new engine and those several different engine platforms. The engines. of this charge air pressure is essential for the already operating Wärtsilä engines. Wärtsilä Electronic wastegate gathered more optimum running of the engine at all times. The development of the new Wärtsilä than 20,000 hours of on-engine testing The Wärtsilä Electronic wastegate and its Electronic wastegate was made in close before it was released for production. The 30 in detail in detail 31 [ MARINE / IN DETAIL ] WÄRTSILÄ TECHNICAL JOURNAL 02.2017
] Integration hardware including shaft coupling Electrical actuator The load on stability
Key points of the Wärtsilä Electronic wastegate valve for new engines as well as for engines already in use. / IN DETAIL MARINE
[ The Wärtsilä Electronic wastegate is now a standard feature on all Wärtsilä 31 engines, all Wärtsilä 46DF engines and on all new Wärtsilä 20V34SG and Wärtsilä 18V50SG engines. Wärtsilä Electronic wastegate is available Butterfly valve as an optional upgrade on Wärtsilä 34SG engines to allow the charge air pressure to be adjusted depending on the engine speed and load. An upgrade on an older engine yields faster valve reaction time and improves engine stability. Comprehensive operation data, such as the actual valve position compared to its set position, allows for better diagnostics.
validation process also included an 8000- Wärtsilä Operation Interface System, for valve Irrespective of operational profile – if the hour field test on a Wärtsilä 20V34SG diagnostics. Previous control systems of this engine has a base load output, or is used engine at a power plant in Turkey. type used electro-pneumatic systems, but the as backup – Wärtsilä aims to support its The Wärtsilä Electronic wastegate and wastegate system is electrically activated with customers with intelligent solutions. its built-in diagnostics capabilities make it a high-speed electrical motor making it faster, possible to know what is happening inside more responsive and accurate, and trouble-free. Bottom-line impact the actual valve of the engine, whereas With the information it provides, the The Wärtsilä Electronic wastegate is an previously the only known factor was electrical wastegate-equipped engine is more intelligent product from a lifecycle perspective what was requested of it, such as the actual stable and more efficient. The precision because it has a positive impact on an valve position compared to its set position. diagnostics also improve condition-based engine operator’s bottom line by minimising Another advantage is an alarm signal if a monitoring. downtime due to fewer overhauls. set point gets exceeded. All this yields faster It must be noted that it was a challenge engine reaction time, improves engine Precision cooperation to develop the electronic (software and stability and improves the parameters The Wärtsilä Electronic wastegate was sensor-based) wastegate valve system due required for condition monitoring. originally developed for new engines but the to the harsh environment these engines benefits as a retrofit on older engines soon work in, and the high exhaust temperatures, Small footprint became apparent for the Services division. vibrations, and moving parts. The Wärtsilä Electronic wastegate upgrade on The system was developed in collaboration Another challenge was to adapt the Wärtsilä 34SG engines requires only two days between the departments and the project system to the changing needs of power to install and its footprint is equally discrete, serves as an example of innovative way of plant customers where loads peak at measuring less than one metre in length and working within Wärtsilä. different hours, ramping up and ramping weighing around 20 kilograms. Not only does Putting the Wärtsilä Electronic wastegate down production, depending on the need it fit into existing engine layouts, the system into context, the effort is part of a company- for electricity in the grid. This variable is service-free and requires minor piping and wide initiative to digitalise engine operations load profile creates special temperature hardwire connections, and some thermal to help maximise performance, reliability and pressure requirements on ancillary insulation. It works seamlessly with WOIS, the and thus business benefits for customers. machinery and systems. 32 in detail in detail 33 [ MARINE / IN DETAIL ] WÄRTSILÄ TECHNICAL JOURNAL 02.2017
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Operation flexibilities: an efficient the heavier hydrocarbons to Liquid VOC further equipped with Wärtsilä LNGPac to use of the installed machinery and (LVOC) that is stored in a tank on the deck enable operation in gas mode throughout propulsion systems in the vessel secures of the vessel. the shuttle tanker operation with LNG as an unmatched manoeuvring capability The lighter hydrocarbons that are not primary fuel for the engine. while the built-in system redundancies liquefied, referred to as Surplus VOC With both LNG and LVOC onboard, ensure an inherent system robustness (SVOC), which mainly consists of methane Wärtsilä started to develop and performed / IN DETAIL MARINE [ when managing unexpected events. gas, will be burnt in a gas turbine for testing of the possibility of mixing LNG with Improved economics: 22% reduction in electricity generation, chosen because LVOC in gas form for potential valuable fuel total fuel consumption and with the use of the two times better efficiency than for the engine. VOC as fuel, resulting in considerable the traditional use of boiler with steam LVOC comprises heavier gas reduction in bunkering needs, and generator. hydrocarbons such as propane and butane combined with fewer running hours hence From a typical North Sea platform that have relatively low methane number lower maintenance costs for machinery. installation, each crude oil loading of a (MN) of 25, making them less suitable cargo size of 850,000 bbls, will recover 100 as fuel for our gas engines (to avoid Reduced emissions tonnes of LVOC and 10 tonnes of SVOC. By knocking). By mixing the LVOC with During operation, conventional shuttle avoiding these amounts of VOC escaping LNG with an MN between 70 and 90, we tanker design has high levels of emissions, into the atmosphere, the yearly reduction of will achieve an acceptable MN for the gas mainly from the emissions of VOC to the emission goes from 43,000 to 25,000 tonnes engine at any required power. Depending
atmosphere during loading, storage, and of CO2, i.e., a reduction of 42%, assuming on the MN of LNG the engines will run a transportation of crude oil. For instance, around 32 loadings per year. maximum continuous rating (MCR) less the storage and loading of crude oil onto than 100% due to the de-rating mode. This ships are responsible for more than 50% of Use of LNG and LVOC as fuel for engine de-rating mode is fully acceptable due to Norway’s VOC emissions. The Norwegian Today’s shuttle tankers are equipped with the operational flexibility built into the new authorities have thus implemented stringent direct propelled 2-stroke diesel engines Shuttle Tanker concept. (Figure 1) emission reduction regulations for all running on heavy fuel oil (HFO) or marine Utilising LNG as the primary fuel and The new Shuttle Tanker shuttle tankers loading crude oil from gas oil (MGO) and the recovered LVOC has LVOC as secondary fuel, the new Shuttle offshore processing platforms located in the so far been considered as a waste product. Tanker enables the utilisation of 100% of the Norwegian continental shelf. The 2-stroke engines are mainly used for recovered LVOC as fuel for electric power The loading operations take place when propulsion during transit, and the 4-stroke generation. (Figure 2) AUTHOR: Stein Thorsager, Business Manager, Wärtsilä Gas Solutions crude oil is loaded to the Shuttle Tanker auxiliary plant is providing power for the mail: [email protected] directly via a loading hose connected to extensive thruster system used during DP Operational flexibility a Floating Production Storage Offshore operation. The power distribution system will be (FPSO) unit, fixed platform or via a loading With an average of 100 tonnes of based on the Wärtsilä Low Loss Hybrid buoy. This operation can take place in harsh recovered LVOC per loading, the recovered (LLH) system using batteries for further environments and with difficult sea stages. amount could represent up to 30% the total fuel savings, peak load shaving and added The new Shuttle Tanker concept It is raining innovations in Wärtsilä. The (DP) condition, transit in laden, unloading The crude oil need to be loaded with high fuel consumption of the Shuttle Tanker overall system redundancy. developed by the world’s largest provider new Shuttle Tanker concept allows tankers and ballast conditions. transfer speed to ensure predictability in should we be able to use the LVOC as fuel. Wärtsilä LLH does not only offer of shuttle tanker services, TEEKAY, in to operate both on Liquefied Natural Gas All of these operating modes have weather conditions throughout the DP TEEKAY has therefore replaced the the highest efficiency over all electrical close cooperation with Wärtsilä, will offer (LNG), as the primary fuel, and Volatile their own requirements, but traditionally operation. conventional 2- and 4-stroke engine components, but a great benefit comes a new level of ecological and economical Organic Compounds (VOC) – which is the these requirements have led to equipment During the offshore crude oil loading, configuration with fully electric propulsion from its superior capability to minimise the solutions by using Wärtsilä’s high-quality environmentally harmful gas evaporating installed on board not being used efficiently the VOCs are emerging from the crude oil with generator sets driven by Wärtsilä impact of a failure during DP operation. equipment and systems in innovative from the oil cargo tanks – as secondary fuel. in the various operation modes. cargo tanks and must be captured by a VOC 4-stroke dual-fuel (DF) engines. In addition to the required trial speed of ways. Find out how this has reshaped the The new innovative solution aims to reduce The new Shuttle Tanker will have the recovery plant, avoiding harmful emissions With electric main propulsion motors the vessel, the size and functionality of the
business of the industry. annual emissions of CO2 equivalents by up to following three features compared with a to the atmosphere and 4-stroke DF generating sets as the only power plant is determined from the power 42% compared to conventional shuttle tanker. conventional shuttle tanker: Wärtsilä has long experience in power plant onboard the vessel, flexibility requirement in DP condition. While a The reduction equals the emissions from Reduced emissions: VOC emissions developing VOC recovery plants that and overlapping functionality is achieved. traditional electrical distribution system 22,000 cars per vessel per year. from the cargo will be eliminated, the can satisfy the requirements from the This power distribution concept is part of could lose more than 50% of installed power The main task for a shuttle tanker is to NOx from the engine exhaust will be Norwegian authorities. With these Wärtsilä Low Loss Hybrid concept reducing and several thrusters, the LLH will lose only transport oil from offshore fields to land- reduced by 84% which is well below IMO experiences, Wärtsilä has now designed a the total installed power on board from 26 25% of the installed power and not more based oil terminals. As shuttle tankers Tier 3 levels, while the SOx emissions will new generation of VOC recovery plant that to 23 MW with further reductions in fuel than one thruster. operate in offshore conditions, these vessels be practically eliminated, and finally the will satisfy also the more stringent authority consumption and resulting in an increased Thanks to the LLH system, the system are the most advanced merchant vessels particles will be reduced by more than requirements expected from 2030. overall efficiency of the vessel. efficiency is improved and together with with unique varieties in operation modes 96%, thus resulting in an astonishing The Wärtsilä VOC recovery plant uses To achieve full SECA and NECA electric propulsion, the required total including loading in Dynamic Positioning reduction of emissions. compression and cooling phases to liquefy compliance, the new Shuttle Tanker will be mechanical installed power will be reduced 34 in detail in detail 35 [ MARINE / IN DETAIL ] WÄRTSILÄ TECHNICAL JOURNAL 02.2017
] RelativeRelative MCR MCR vs. vs LVOC LVOC Mass % in LNGMass Mixes %– W34DF in LNG Mixes - W34DF LVOC + LNG (MN90) LVOC + LNG (MN80) LVOC + LNG (MN70) 120 %
111 %
102 %
93 % / IN DETAIL MARINE [ 84 %
75 % cyl)
66 %
57 %
48 %
39 % Fig. 2 - With an average fuel consumption of 8750 tonnes per year, 3200 tonnes will be generated and used onboard as LVOC. Relative Maximum Continuous Rating (100% = 480kW/ Relative 30 % 0 13 25 38 50 mass-% of LVOC in mix
Fig. 1 - Relative MCR vs. LVOC Mass % in LNG Mixes – W34DF
by 14%, which will improve overall fuel engines will get a stable load and therefore Management System (BWMS) named performance compared with traditional could operate in a higher load area without AQUARIUS® EC. It uses an in-situ chlorine power distribution concepts. risking the startup of additional generators generation technology known as electro- As a result of the new Shuttle Tanker due to transient load variations. The New chlorination (EC). AQUARIUS® EC is a concept, the total energy consumption Shuttle Tanker is the first ship of this size modularly designed BWMS. The system will go from 110 GWh to 75 GWh per year utilising batteries for improving efficiency is installed in a bypass loop to the main compared to a traditional shuttle tanker. during transit operation. ballast line to provide a safe, flexible and With increased efficiency, we will also For crude oil offloading operations at economical process for the treatment of improve the DP (manoeuvring) capability. A the onshore terminals, Wärtsilä can supply ballast water and eradication of aquatic conventional system will use 60% of thruster either electric-driven pumps for pump invasive species. power, whereas in LLC concept only 40% room installation, or electric-driven deep Fig. 3 - The new Shuttle Tanker is the first ship of this size utilising batteries for improving efficiency. will be used, thus giving the master a much well cargo and ballast pumps that enable Improved economics better manoeuvring capability. a distributed pump solution, eliminating The new Shuttle Tanker concept represents Moreover, the LLH electric equipment the need for a separate pump room and an absolute game-changer for the shuttle room is more compact compared to a interconnecting pipelines in the cargo holds. tanker sector. To put it in simple terms, the conventional electric room. The Shuttle The space gained from eliminating the concept enables shuttle tankers to travel operation of the new Shuttle Tanker vessels, These benefits have been made possible production in Norway and the UK will be Tanker power distribution system utilises a pump room can be used either to increase from the oil fields on its own waste gas to accomplish a total life-cycle solution to with Wärtsilä’s advanced technology and transported to land using shuttle tankers. Low Voltage arrangement also with excess of the cargo capacity or to shorten the engine rather than releasing it in the atmosphere. the owner. Such support and assistance through integration capabilities between About 40% of this existing tanker fleet is 23 MW of installed power, which will again room with a shorter hull, giving lower Both emissions and bunkering requirements will comprise both training of the crew different business segments in Wärtsilä ready for replacement due to the 20-year age have a large benefit for the crew on board. building cost and better DP capability will be considerably reduced and the chosen and the officers for the equipment and the supplying the various equipment and systems. limitation for new shuttle tankers. When installing batteries on board, the thanks to the leaner side profile. propulsion solution will increase overall systems together with varied technical and We see an exciting time ahead for vessel has a hybrid energy system that will With the efficient and environmentally efficiency compared with conventional operational real-time online support and Market potential similar contracts in the near future for this continuously support the dynamic capacity of friendly electric power plant installed on systems. monitoring. Such operational follow-up TEEKAY has contracted two firm and two ecological and economical Shuttle Tanker the energy production system and, through board the vessel, electrical-driven pumps for With this concept, the overall running directly with the owner is crucial to ensure options of the new Shuttle Tanker vessel at concept developed in cooperation with the stored energy of the batteries, enable cargo off loading and ballast are utilised in hours will be lower, which will mean lower that the vessel achieves the objectives set Samsung in Korea, all based on Wärtsilä’s TEEKAY and Wärtsilä. engines to operate in a load area where fuel the most efficient way. maintenance costs for machinery. for the new Shuttle Tanker in respect to high-quality equipment and systems in this consumption is optimal. The batteries will In connection with ballast pumps, Wärtsilä is also ready to support and emission reduction, fuel efficiency and with new and innovative concept solution. handle the dynamic load variations and the Wärtsilä can supply its Ballast Water provide active assistance during the operational flexibility. We estimate that half of all offshore oil 36 in detail in detail 37 [ MARINE / IN DETAIL ] WÄRTSILÄ TECHNICAL JOURNAL 02.2017
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A decision taken by the Hollywood movie required for cold ironing and the ship installation, meaning the cable connections legend Arnold Schwarzenegger in 2006, owners have to install and integrate them between container and vessel connection when he was the governor of California, on the ships themselves. Some provide point are screwed into place. This is the has had far-reaching consequences for container solutions, but they don’t install solution for vessel owners who intend to fix the business of Wärtsilä Electrical & the containers and equipment on the ships. the containers in place for long periods of Automation. The ‘Terminator’ opted to In contrast, Wärtsilä’s approach involves time. Another option is the plugged solution promote shore power, known as ‘cold high-level engineering from the cable reel which requires Wärtsilä to fit a second ironing’, or ‘Alternative Marine Power’, to plugs until the main switchboard, from cable reel next to the shore connection reel. reduce pollution and greenhouse gases connection on the shore to synchronisation The extra cables with plugs connect the from the state’s ports. As a direct result, with the ship’s network. Teams of about six container to the vessel’s connection point California became the epicentre of shore engineers take care of the installation of with installed sockets and allow customers power and there was a boom in business for the SAMCon system. Wärtsilä’s expertise to take the containers off the vessels at Wärtsilä SAM Electronics, which provides involves onboard visits and offers different short notice. It means they can remove a its SAMCon cold ironing container solution solutions so that customers can choose what connection and take the container off in 15 to cargo ships. suits them. minutes. A third option includes adding a Cold ironing is the process of providing The Wärtsilä process begins with the ‘step down transformer’ to the containers. electrical power from the local grid to a modification of standard, empty containers. Shore power is always 6600 volts and some ship at berth in a port while its engines are The vast majority are 40ft high cube low-voltage vessels have only 440 volts so a turned off. It allows refrigeration, heating, containers, but 20ft ones are also available as transformer is required. lighting, and other equipment to receive an option. Wärtsilä’s team creates openings Some ship owners reject the container power as it unloads. Cold ironing provides for the cables, insulates the containers and solution and ask for the components to cleaner power for ships at berth in ports by fits the components, including a medium- be taken out and fitted on board. This is connecting them to local energy sources voltage cable reel, a cable reel control box because they think the ship is too small so they can continue to run electrical and a medium-voltage switchboard. A to accommodate the containers or that it equipment while unloading. Many ships container may also include a transformer, might be a cheaper solution. However this are equipped to carry out the process when or a second cable reel for the connection to approach doesn’t save money as it involves built, but others have to be retrofitted. As the ship, which depends on the customer’s more coordination work for Wärtsilä’s Wärtsilä engineers offer a result of Schwarzenegger’s legislation, specifications. SAMCon container features engineers than installing a container Wärtsilä has carried out more than one include an electric cable reel drive, including and it is also less flexible. Once the large technical solutions for cold ironing hundred retrofits for ship owners going into tension control, and a shore interface components are welded into place it is also ports of California. Wärtsilä’s customers designed for the ports of the west coast of much harder to remove them than it is to include major shipping companies carrying California and therefore IEC 80005-1. The take off a container. So, when they have cargo from Asia and Europe to the US. system is made to provide up to 7.2MVA been fitted on board and the vessel takes AUTHOR: Jürgen Zabel, Senior Manager, Power Conversion, Wärtsilä SAM Electronics transferable power at 6600 Volts and 60 Hz. a route that doesn’t offer shore power, the mail: [email protected] First container solution components tend to be left on board unused The first cases of cold ironing were in the Engineer checks while the vessel sails around the world. cruise industry, in Alaska, in 2001. But LA Wärtsilä’s engineers check the vessels started to use the process for commercial carefully to find the best cableways, Flexible system ships three years later and around the same installation possibilities, and location to The onboard inspection takes around three Wärtsilä Electrical & Automation has time, Wärtsilä SAM Electronics produced install the containers. Usually, they are hours. During the boom years of 2012 and carried out more than 100 installations the first container-based solution, which placed on a standard container slot above 2013 the team was visiting vessels around the of its container solution SAMCon for ‘cold means installing the components required the winch deck. They are always on the world every week, depending on where the ironing’ to connect cargo ships to local to connect the vessel to the shore power in a outer edge – port or starboard side – of the ships were sailing. Wärtsilä has to be flexible power sources at California’s ports. container and fitting it onto the ship. vessel. Sometimes they are stationed in front as ship owners change routes at short notice Many suppliers provide only the most or just behind the accommodation area. and the teams could be asked to fly long basic services. They supply the components Many customers choose a ‘bolted’ distances. An ideal installation would be 38 in detail in detail 39 [ MARINE / IN DETAIL ] WÄRTSILÄ TECHNICAL JOURNAL 02.2017
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Connection between container and ship: plugged type.
Connection between container and ship: bolted type.
Connection solution.
in Europe, but it usually doesn’t work out Market opens up ironing is becoming more common. The that way. Ship owners won’t want to take There are signs, however, that the market is Chinese government has recommended the vessels out of service so the Wärtsilä opening up. Outside the US, several ports cold ironing to be part of the construction installation teams fly around the world to in Scandinavia are offering shore power, for all new bulk and cruise terminals. For join the vessels. Wärtsilä technicians might but they serve the ferry industry, which cargo vessels, the harbour in Ningbo has have to fly to China, load the materials for requires a different type of installation. already been modified. Altogether, seven Connection between container and two days, then stay with the ship to do the Wärtsilä also offers cold ironing solutions Chinese terminals are in testing mode. This ship: bolted type. assembly and connection works until it for ferries and cruise liners. Furthermore, year, V.O. Chidambaranar Port in Tuticorin, reaches California. in Canada, the government provided USD India, became the first to offer cold ironing. California continues to set the pace for 27.2 million to implement cold ironing in Going forward, both China and European cold ironing. By 2020, 80% of the ships Halifax and Vancouver ports. In Europe, nations could provide more ships to need to be ‘compliant’. A ‘compliant’ call Sweden, followed by Germany, Belgium, Wärtsilä for retrofit. This spells good news is reached if a vessel needs less than three Norway, and The Netherlands, have already for the company, since it can then develop hours for arrival, connection to shore power, moved towards this solution, mainly for and reach new markets for cold ironing. disconnection, and leaving the harbour. Few ferry and cruise berths. Additionally, a places have such a strict regulatory regime 2014 EU directive mandates member states as California, however, and in 2012 the to implement alternative infrastructure International Maritime Organisation (IMO) networks, including shore power, by 2025. discussed making shore power mandatory In the long-term, the IMO’s Marpol 6 at all the world’s ports. At the time, the IMO regulations, which aim to progressively Connection between container and ship: concluded there were not enough ports – reduce the emission of fuel particulates NOx bolted type. only around 20 – ready with the technology and SOx, should encourage shore power. to make it viable. In Asia too, there are indications that cold 40 in detail in detail 41 [ MARINE / IN DETAIL ] WÄRTSILÄ TECHNICAL JOURNAL 02.2017
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Wärtsilä HY – Diesel-mechanical.
Achieving full hybrid potential by one, the automotive industry has for years What is Wärtsilä HY? electrical components one integrated championed the use of hybrid technology, The Wärtsilä HY integrated power module product, whereas previously this integration or battery-assisted propulsion. As a result, consists of a smart and well-driven was an afterthought stitched together by mastering synergies battery costs have dropped while their combination of mechanical power and different suppliers. This harmonisation performance has increased, shoeing in energy storage. It is the culmination of creates an entirely new level of interaction hybrid technology into other fields such Wärtsilä’s industry-leading expertise in between its internal components and as shipping, where traditional engine both engines technology and electrical with the ship’s onboard systems, thereby AUTHOR: Corinna Nones, Manager, Applications Developments, Wärtsilä Italia technology is now quite mature. and automation systems, including hybrid providing enhanced operability and greater mail: [email protected] Boosting ship performance has been on applications, and is the result of a unique predictability. the wish list of many operators. Stricter range of in-house competencies. Specifically, this unified EMS means that environmental demands are also looming What differentiates the integrated the energy flow is optimized to achieve ahead for the industry. Wärtsilä HY module compared to a the best performance in each operational Hybrid propulsion is expected to be the traditional hybrid system is that Wärtsilä mode. This kind of total control was not Wärtsilä HY is the first integrated hybrid For vessels like tugs, ferries, dredgers and Rimorchiatori Riuniti, the biggest tugboat technology of choice for a substantial part delivers the whole package so that all the possible when an energy storage system power module in the marine market. An others, this single Wärtsilä HY hybrid operator in Italy and the Mediterranean, of the shipping industry in the near future. elements can seamlessly work together was simply added to the mix without all alternative to belching smokestacks, this power module represents a giant stride signed a historic deal with Wärtsilä to Technological advances have reached such controlled by one integrated software the corresponding components working in green and efficient propulsion module was towards achieving a greener international contract the Wärtsilä HY integrated hybrid a level that the incremental improvement system, the Energy Management System, or unison. developed by maximizing synergies in the fleet, cutting costs and improving vessel power module for its fleet of 60 harbour of conventional diesel engines is just EMS. Some call it the ‘brain’ of the system. In order to match the specific demands group. With Wärtsilä as a single supplier, performance and services. tugs, 18 offshore vessels and three ocean not enough anymore as any small gain Using batteries for marine propulsion of different market segments, Wärtsilä HY it is a new benchmark in alternative Wärtsilä HY was unveiled in May 2017 going ships. requires disproportionate resources. What is not new per se, but the Wärtsilä HY comes in highly customizable forms which propulsion. at the Nor-Shipping trade fair in Norway is required instead is a drastic change of marine hybrid power module is special is made possible by tuning the proprietary and has already achieved the ‘Approval in Hybrid is now mindset to go beyond the physical limits of because it is a single innovative product EMS software and by optimally sizing the Principle’ classification with Lloyd’s Register. Some key macro trends are responsible the individual product. And this is where steered by the EMS software. This core internal components. At the event, the Genoese tug operator for the Wärtsilä HY roll-out today. For Wärtsilä HY comes into play. or ‘brain’ of the Wärtsilä HY makes the The standard mechanically-driven 42 in detail in detail 43 [ MARINE / IN DETAIL ] WÄRTSILÄ TECHNICAL JOURNAL 02.2017
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An eco-friendly tug
Wärtsilä’s new portfolio of tug and a 35m escort tug with a 75t Applying hybrid technology is configuration includes a main engine optimised for specific operating profiles technological leadership in both engines designs emphasises environmental bollard pull, delivered via Wärtsilä expected to reduce harmful emissions with clutch, an in-line shaft generator/ be they tugs, ferries or dredgers allowing and electrical & automation systems to set a sustainability. They draw inspiration WST thruster series. The propulsion and achieve operational cost savings motor, an energy storage system, DC ship operators to attain efficient power new industry benchmark in marine hybrid from Wärtsilä HY technology – which configuration is such that each design when compared with conventional link and power drives and the EMS. The management, flexible layout solutions, and propulsion. Through combining its unique / IN DETAIL MARINE [ provides flexibility and efficiency to comes with the option to select tug designs. In addition to the hybrid standard electrically-driven configuration reduced noise and vibration, among other range of in-house competences, Wärtsilä has the operation of the tug – and the either diesel mechanical hybrid or technology, LNG-fuelled engines includes a generating set, an energy storage benefits. turned a complex system into an innovative company’s proven LNG technology. diesel electric hybrid propulsion, and thrusters, Wärtsilä will also system, a DC link and power drives, and single product that delivers unrivalled and The Wärtsilä HY Tug designs have and the designs are able to cover a provide shafting and control systems, uses the EMS as well. The advantages guaranteed performance. The module is been created in close cooperation 40 to 90t bollard pull range with the meaning the entire propulsion system With the Wärtsilä HY onboard, directed by tailor-designed for individual vessel market with the ABS, BV and Lloyds Register appropriate Wärtsilä equipment. will come from a single supplier. This the EMS‚ a tug for example can sail out of a segments and can be optimized for specific classification societies, and have The technology represents enables full integration of the overall How it works densely populated port in ‘green mode,’ i.e. operating profiles, thanks to EMS. And received the Approval-in-Principle a unique innovation in marine system for greater efficiency, while The Wärtsilä HY configuration is based not powered exclusively by the batteries, and with Wärtsilä as a single supplier for all this, (AiP) certification. The new tug propulsion systems. Through its also reducing possible scheduling only on the maximum power demand of then assisting operations can be carried out performance is guaranteed. designs feature a very distinctive in-house expertise in engine design risks for the owner and shipyard. the ship, but also on its specific operational with the diesel engines on and the batteries outlook while providing the power and electrical & automation (E&A) The new tugs will, going forward, profile (i.e. how much power for how then cover all the load peaks and power and manoeuvrability for practical systems, Wärtsilä has developed a rely more and more on battery and long, mode of operation, etc.). The time instantaneously. The air quality impact of tug operations. Its total installed fully integrated hybrid power module hybrid propulsion, which complement factor also enters the equation, and the shipping in populated areas is thus reduced. main engine power is less than the combining engines, an energy storage today’s tug operational requirements. dimensioning approach evolves from Another finesse of Wärtsilä HY is the conventional hybrid tug designs, while system, and power electronics. These With unmatched in-house capabilities power-based to energy-based. And an cold-systems start-up, which essentially does maximum bollard pull is achieved via are all optimised to work together combining ship design, engine optimal balance between engine power and away with the need to wait for the engines power boosting from the batteries. through a newly developed energy technology, propulsion and E&A energy storage leads to a more compact to warm-up prior to operations. This is These newly launched Wärtsilä HY management system (EMS). It is solutions, Wärtsilä’s new tug designs design which requires fewer cylinders instead overcome by the energy storage Tug designs come in three different the marine sector’s first produced are uniquely positioned to meet the running at a higher efficiency loading rate. system leading to instant ship readiness. hull sizes, namely a 28m harbour hybrid power module of this type, future needs of the industry. This of course reduces maintenance costs in This instant availability of energy stored in tug with a 50t bollard pull, a 29.5m thereby establishing a new industry Stay tugged. the long term. the batteries is also a safety measure. This harbour tug with a 75t bollard pull, benchmark in hybrid propulsion. In its Diesel-mechanical version, Wärtsilä stable and efficient engine loading is due to HY uses two separate key components: an the EMS peak shaving function where load internal combustion engine and an electric fluctuations are absorbed. motor/generator, the latter being connected With the Start & Stop functionality, at to the electrical grid (hence to the energy low loads, the power is supplied exclusively storage system). These components work by the energy storage system until it in synergy with each other allowing for reaches a pre-set minimum state of charge. instant load-taking, green mode, start&stop, At this point the engine is automatically peak shaving, power boost, hence more activated, providing power to the ship and redundancy, higher safety, less engine simultaneously re-charging the energy running hours and higher efficiency. All storage system. these features can be obtained with even Central to all of these advantages is an more ease in the Diesel-electric version, increase in operational efficiency, which where the combustion engine can directly in turn reduces fuel consumption and generate electrical power through a emissions. generator. In fact, in “green” mode, there are Furthermore, the EMS is finely tuned to zero emissions, while in all modes – the vessel’s design and operational profile from start-up to full power output – the throughout its lifecycle. This guarantees that operation is free of visible smoke, thanks to every specific ship is designed and operated a new Wärtsilä patent-pending procedure. in the best possible way, according to the Additionally, the reduced engine operating actual operating profile. time lowers the maintenance requirements Generally, hybrid power systems improve because the engines are running fewer hours fuel efficiency and reduce emissions quite in total. simply because batteries are used to do some The Wärtsilä HY also comes with entire of the heavy lifting instead of diesel engines. system certification. In the case of Wärtsilä HY, the package is To summarize, Wärtsilä has leveraged its 44 in detail in detail 45 [ ENERGY FUTURE / IN DETAIL ] WÄRTSILÄ TECHNICAL JOURNAL 02.2017
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seemed a logical step in the CDC. distance of two metres per second. The kilometres of walking in the warehouse in Innovation and robotics are essential for robots navigate using a 270-degree laser Kampen each day. Wärtsilä, and are one of the key points in the scanner combined with a 3D camera. For “Carrying boxes from A to B is not a partnership with DHL. visualisation, the robot projects a blue light really valuable task. Instead, employees can Faster, easier, and safer Teija Tikkala, Manager of IT Service two metres in front of the robot. concentrate on other jobs,” Tikkala says. She Management in Wärtsilä Global Logistics adds: “Some of the warehouse operators will Services, Parts Delivery, says now is the Smooth interaction with humans become a ‘robot key user’ and also configure together with robots right time to start using robotics. “It’s no Before the pilot was launched, the staff new tasks for the robots.” longer a massive investment. The costs are received information about the robots – getting more realistic and implementation is for example, how they move and what load User friendly easy. There is also more technology related they can carry. The Information Corner was All in all, Tikkala believes, most employees AUTHOR: Thessa Lageman to smart autonomous machines available set up to share details about the robots and were pleased with the robots. “People like and the developments go fast.” progress of the pilot. how easy it is to use them.” There was no Early involvement of the staff is need for complicated programming, for Small mobile freight robot important, Tikkala emphasises. People had a example. Also, only minimal warehouse In a recent one-month pilot Wärtsilä The warehouse staff normally carry the 37,000 square metres, and it stocks over The aim of the pilot was to explore the lot of questions and also concerns about the changes were needed: floor striping to mark ran with logistics company DHL, four boxes themselves or use a pallet truck, 80,000 unique parts, with some 27 million options of using the latest technology robots and how robots would impact their the robot’s parking and charging spots. small freight robots carried plastic bins but now they placed them on the robot different pieces. Last year, over 100,000 innovations in the warehouse’s daily daily work. “They also had a lot of great The pilot is regarded as a success for a and carton boxes in Wärtsilä’s Central shelves and pushed a button on the robot’s deliveries were shipped from this CDC to operations, she explains. “Wärtsilä and DHL ideas how we should utilise the robots in the number of other reasons too, she explains. touchscreen. The material transport robots more than 180 different countries. On an also wanted greater insight into the added warehouse. So we arranged an idea contest The stock availability has increased, having Distribution Centre (CDC) in Kampen, the then set off on their pre-defined route to average, this means 35 trucks departed each value of robotics in a storage environment and then selected the pilot use cases from more continuous material flow has reduced Netherlands. The outcome was so posi- their destination in the CDC. Here, DHL day. and into the interaction between robots and those ideas.” some buffers, and thus efficiency and tive that the robots are here to stay! operates some of the warehouse activities, Even though the storages are already employees.” The use of robots results in more productivity have improved. “And of course like goods reception, picking, and packing. fully automated, there are still quite a Fetch Robotics, a California-based rewarding responsibilities and tasks, she we are proud to be part of this kind of new The floor space of the distribution high number of manual boxes and pallet company, provided the hmishelf25-type explains. The robots relieve the warehouse innovations and the positive publicity this centre in Kampen, a small Dutch town movements between the various work robots. These small models have a loading operators from physically strenuous work has brought to Wärtsilä.” 90 kilometres northeast of Amsterdam, is stations. This is why further automation capacity of 75 kilograms and can cover a and, based on pilot findings, more than 30 The company has now decided to 46 in detail in detail 47 [ FUTURE / IN DETAIL ] WÄRTSILÄ TECHNICAL JOURNAL 02.2017
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purchase three robots to support the docking station,” recalls Tikkala. An efficient Robot dance An hour later the cause was found. “The robots are used for the same task or running other robot types and technologies. “We’re operation within the CDC in Kampen. set-up and operation requires a Wi-Fi Initially the robots had some difficulties software has been adjusted, and the robots on the same path, so you can program them thinking of investigating larger robots like There are no plans yet to use them in other connection with sufficient range. seeing certain objects, like the reflective recognise the vests now,” Tikkala smiles. to know who goes first.” the freight500, for instance, which can carry locations, but Tikkala thinks this is likely in The robots are intelligent. They recognise stripes on the DHL global standard safety On another occasion, two robots faced more and heavier parts.” the future. their locations and surroundings, and can jackets. “The 3D camera got confused by each other on their way to the charging unit Larger and more complex Early next year, Wärtsilä plans to start a differentiate between dynamic and static the highly reflective vests and saw ‘speeding to reload. When the nine-hour battery life Over the coming months, the trial will pilot with drones, which could be equipped Wi-Fi connection obstacles, enabling evasive action for working ghosts’. The result was that the robot had ends, the robots independently make their continue in Kampen to further improve with a camera to calculate stock and gather Naturally, a few lessons were learned during safely with and around people. Apparently difficulties to navigate through what looked way there. “They were programmed to avoid productivity, quality, and safety. “For the other information. the pilot and some things will be done it is even safer to work with robots than like an empty space for us.” contact and started a sort of dance around first pilot we selected fairly simple tasks and “Like we did in this first pilot, we will also differently next time. “One of the challenges without them. “Robots have built-in sensors During the grand opening of the pilot, with each other,” says Tikkala. “It looked quite routes,” says Tikkala. “Now we can extend the gather the ideas for using drones from our was the blind spot in our Wi-Fi network, that recognise movements, which the pallet dozens of visitors wearing a reflective safety funny.” route, and add more complex itineraries.” personnel. People have a lot of good ideas,” which made the robots stop or return to the trucks don’t have,” Tikkala says. vest, the robots suddenly became disoriented. She adds: “This can of course happen, if There are also plans to experiment with says Tikkala enthusiastically. 48 in detail in detail 49