2010 Travel report

Dispuut Vulcanus

04 July 2010 – 09 July 2010 Travel report

Preface This travel report is the closure of a highly successful VST 2010 (Vulcanus Study Tour). On the early 2 morning of the 4th of July a group of 22 Vulcania gathered at the 3ME-building, to start our yearly foreign trip. This year we were heading for Germany and Switzerland, to be more precise: Augsburg, Winterthur, Friedrichshafen and Zurich. Everybody was looking forward to visit some of the leading companies/research facilities in marine propulsion systems.

Yearly Vulcanus organizes a Study Tour to foreign companies in our field of study. The marine industry is an international industry but due to our limited budget we concentrate to maritime companies within the European Union. The yearly study tour tries to give our members an impression and insight in the field in which they probably will work in the near future. The study tour is also a great opportunity to expand your professional network. Besides from the educational experience, we enjoyed the cultural and nightlife of the visiting cities during this year study tour.

First of all I would like to thank my fellow board members Benny Mestemaker, Dirk Hoek and Frank van Es for their hard work. Secondly, I would like to thank the companies which we visited for their hospitality and interesting presentations. Thirdly, I would like to thank Mr Hugo Grimmelius and Mr Douwe Stapersma for their useful suggestions and contribution to get in contact with the various companies. And last, but definitely not least, I would like to thank our sponsors. Without their contribution it was not possible to organize and finance VST2010.

I hope by reading this year’s travel report it will bring back good memories and motivate the upcoming Vulcanus board to go beyond this year study tour. Enjoy reading and I look forward to next year’s study tour.

Best Regards,

Erik van Deursen

Chairman Dispuut Vulcanus

Travel report

Content Preface ...... 2 3 About Vulcanus and VST 2010...... 4 Participants ...... 5 Program ...... 6 Sunday, Journey to Zürich ...... 7 Monday, visit to ETH Zürich ...... 8 Monday, visit to Paul Scherrer Institute ...... 10 Tuesday, visit to Wärtsilä Winterthur ...... 13 Wednesday, visit to MTU Friedrichshafen ...... 16 Wednesday, visit to Zeppelin museum Friedrichshafen ...... 18 Thursday, visit to M.A.N. Augsburg ...... 20 Friday, journey back to Delft ...... 23 Sponsors ...... 24

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About Vulcanus and VST 2010 Dispute Vulcanus is a student association for Master students with the specialism Marine 4 Engineering, Marine Diesel Engines or Mechanical Systems and Integration. Vulcanus provides excursions to companies inside the Netherlands as well as a one-week international business tour each year. Mainly through currently working, previous student-members Dispute Vulcanus has good contact with several companies. Next to periodically getting together at Café de Waag in Delft and some excursions to companies during the academic year, once each year Vulcanus organizes a one- week business tour to a foreign country. During this business tour companies that are related to the Marine Engineering business are visited to get acquainted with the companies in the sector. But of course also to find out about new technologies on the market, to get useful information for your graduation project, to see some nice things in the country, and last, but definitely not least, it is very much about having a good time with your fellow students . The last few years the business tour went to Germany, France, Sweden and Norway and the United Kingdom. This year we went to the southern part of Germany and to Switzerland because a lot of interesting Diesel engine manufacturers are located there, near the Bodensee. The trip is sponsored by some companies. Through the document and on the last page of this document you will find which companies made this trip possible. Because this trip could not take place without the support from our sponsors, so: Thank you very much!

The trip is organized by the Vulcanus board, this year consisting of (from left to right) Erik van Deursen (chairman), Dirk Hoek (treasurer), Benny Mestemaker (secretary), Frank van Es (vice- chairman).

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Participants This year’s studytour group consisted of a mixed company. There were first year master students, 5 even 2 Bachelor students, 2 Master students from the Royal Netherlands Navy, some Master students who are working on their graduation, 4 PhD students from the Marine Engineering section and members from the staff.

From left to right: Douwe Stapersma, Peter de Vos, Hugo Grimmelius, Kasper de Ruyck, Stef van den Bergh, Erik van Deursen, Michiel Drijver, Dirk Hoek, Bas Kwasieckyj, Frank van Es, Benny Mestemaker, Ding Yu, Ziru Li, Mike Loonstijn, Andries van Wijhe, Wei Zheng, Paul Wattez, Wei Shi, Erik-Jan Boonen, Erik Versluijs

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Program Sunday, 4th July 6 Journey to Zürich (Switzerland)

Monday, 5th July Morning: Visit ETH Zürich (presentations about the HERCULES project)

Afternoon: Visit Paul Scherrer Institute

Tuesday, 6th July Visit Wärtsilä Winterthur (presentations about two stroke Diesel technology and tour through Diesel Technology Center)

Wednesday, 7th July Morning: Visit MTU factory Friedrichshafen (tour through production/assembly/test facilities)

Afternoon: Visit Zeppelin Museum Friedrichshafen

Thursday, 8th July Visit M.A.N headquarters Augsburg (presentations about new technologies and tour through production/assembly/test facilities)

Friday, 9th July Journey back to Delft

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Sunday, Journey to Zürich 4th of July… 7

Sunday morning 4th of July, the Vulcanus tour left the parking place of Delft University of Technology to start its journey to Swiss and Germany. Everyone was in a good mood looking forward to a nice week with interesting presentations, excursions, sightseeing’s and more.

Although the three (of course Diesel driven) vans left at the same time, every route was different. One van went via Antwerp and Luxembourg to south Germany, the other two vans drove crossed the border with Germany at East part of the Netherlands. Maybe this was because one group was using a route description….. in Chinese.

In the southern part of Germany all vans stopped at the same parking place for the first Vulcanus lunch. After the lunch, the three vans found their own way to Zurich without problems. Some of the guys used the travelling time to recover from a though weekend, so they could start the studytour all fresh.

The inner-city of Zurich was closed due to a fantastic festival (Züricher Festspiele), so the challenge was to find the hotel and a parking place for the car.

After many minutes driving round in Zurich, the hotel and parking place was finally found, and everyone could enjoy the party, which was a very good start of the studytour.

Written by: Paul Wattez Travel report

Monday, visit to ETH Zürich morning of July 5th… 8

It was the morning of the first day of the actual programme of the Vulcanus study tour 2010. We had a lovely hotel in the centre of Zürich. One might say the rooms were hot and it was hard to sleep in. Others made good use of the sedatives offered by the Zürich Festival the night before. So after a good night sleep and a lovely breakfast everybody got ready for the departure to the ETH Zürich.

And after Michiel finally got his tie on with the help of the doctoral knowledge of Stapersma and Grimmelius we were off to the university. Fortunately this was only a short walk up the hill, so we arrived well on time. This gave us a good and early opportunity to make a nice group picture in front of the main building. It was a good thing we had all the time in the world, because setting the camera in self-timer mode happened to be a more time consuming project than initially intended. So there we were, in the summer heat, waiting for the person to come and pick us up. I for one would've died for just a glass of water (not being used to wearing a tie in 30 degrees, or actually wearing a tie in the first place).

The destination within the university was the Aerothermochemistry and Combustion Systems Laboratory (or Laboratorium für Aerothermochemie und Verbrennungssysteme, LAV for the connoisseurs) headed by Professor Konstantinos Boulouchos. A presentation of the Hercules-B project from the ETH point of view was scheduled. Panos Kyrtatos was the person that actually gave the lecture. Professor Boulouchos wasn't available at the time.

Hercules-B stands for: Higher- Efficiency Engine with Ultra-Low Emissions. It is divided into several work packages where ETH Zürich mainly focusses on WP 2 and WP 3, or advanced combustion concepts and multistage turbocharging respectively. Amongst others the presentation contained new developments in CFD calculations to optimise the combustion characteristics in spray, combustion and emission. Because these CFD calculation cannot be too detailed with the present computer power available, a test Travel report combustion chamber was built together with Wärtsilä to validate the simulation against the actual combustion process. The presentation was mostly followed by Ding and his camera. 9

It was a pity that none of the ETH students were present. Otherwise Prof. Stapersma and Dr. Grimmelius also might have given a small presentation about the development in the Hercules-B project from the TU Delft point of view. Because there were no other people present – except for one mystery guest that stayed in the room for about ten minutes before realising he was in the wrong place – there was nothing else planned in the programme for this morning.

So it was lunch time. The meal was all well okay. The payment by Vulcanus might proved to be a bit hard, collecting 20 'students' together for one bill, but it all worked out just fine. Some couldn't show that they were students to be able to get the discount. The cashier didn't quite believe Prof. Stapersma was a student, but somehow Peter de Vos got away with it. Great job!

After lunch it was time to get the vans and to head to the Paul Scherrer Institute. But that's a whole other story in the Zürich chapter.

Written by: Bas Kwasieckyj

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Monday, visit to Paul Scherrer Institute afternoon of July 5th… 10

After a nice meal at the ETH in Zürich we left for a visit to the Paul Scherrer Institute (PSI) in Villingen. The diesel engine of which miller timing measurement results were presented earlier that day was located at this institute. The Paul Scherrer Institute (PSI) is the largest research centre for natural and engineering sciences within Switzerland. World-class research is performed in three main subject areas: Structure of Matter; Energy and the Environment; and Human Health.

At the arrival we were welcomed by Dr. Philipp Dietrich, the operating director of the competence center for energy and mobility. His department focuses on development of more sustainable energy systems. Our visit to PSI started with a trip to the roof of the main building. This location gave a good overview over the facilities of the PSI. The main research topics of the different buildings were presented and some main facts about PSI were mentioned.

After this overview it was time to visit the diesel engine test facility. When entering the facility the massive concrete chassis the diesel is fixed to is the first thing to notice. This massive damper is necessary, because vibrations are undesired at the nanotechnology section in the building next to the diesel lab. The diesel lab with its measurement facilities and ability to perform Miller timing was very impressive and some jealous faces were observed. The Wärtsilä 6L20 is equipped with a double compressor to compensate for the pressure loss due to Miller timing. After taking some pictures and a good look we left the diesel engine lab and took a walk to the proud of the PSI, their proton accelerator.

In this proton accelerator proton beams are accelerated to a speed near the speed of light. This is done in a ring of 288m and after about 186 revolutions the total energy in the ring is 590 MeV. From the ring proton beams are provided to eighteen experimental stations. At these stations research is Travel report performed in the direction of material science, biology and chemistry. The proton beam is controlled with many 11 servers and in case of an emergency the beam is guided into a heat exchanger emergency break. However somewhat out of the scope of marine engineering this was a very impressive facility.

At the end of the tour we thanked Dr. Dietrich with a traditional bottle of Dutch Jenever and a Vulcanus tie. We finished the visit with a drink and drove to Zürich for our last night in hotel Otter.

Written by: Erik Versluijs

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Tuesday, visit to Wärtsilä Winterthur 6th of July… 13

Tuesday 6th of july, Wärtsilä Winterthur

On Tuesday it was time to leave Zürich and slowly head back north again. Our last visit in Switzerland was to Wärtsilä Diesel Technology Centre in Winterthur. Once we arrived we were greeted by chairman Weisser, who would lead our group for the day at the centre.

The presentation started casual with a multi-media presentation about the origins of the diesel engine and the Wärtsilä company. We all really enjoyed this introduction especially the film that was shown. It showed all the major advances in diesel engine technology accompanied by great historic events of the same era.

Emissions - general The first technical presentation was about emissions. Emission control is getting even more important in the design and operation of diesel engines. Especially since five days before our arrival the MARPOL Tier2 standard came in to effect.

At Wärtsilä they combat emissions with adaptations to their engine operation. Instead of using after treatment solutions, Wärtsilä is trying to reduce the formation of NOx and SOx in the cylinder. They achieve this by using electronic engine control. This new line of electronically controlled engines (RT- flex) creates less emissions and more power than the conventional mechanically controlled engine (RTA).

Emissions – injection research After this we got a presentation about the combustion process. Extensive research into fuel injection and swirl phenomena is done by Wärtsilä. For this research they’ve build a combustion vessel which has about the same size of the combustion chamber of a RT 96 engine. With the use of infrared camera’s it is possible to capture images of the fuel injection and its following combustion.

Licensee’s The last technical presentation was about Wärtsilä’s licensee manufacturing process. The big 2- stroke engines that Wärtsilä designs are too big and costly to manufacture in Europe. That is why most of Wärtsilä’s 2-stroke engines are build in China. They explained too us how most of the design and testing was done in Europe, based on this, the blueprints are created which will be send to the licensee’s. These blue prints contain only the specifications of the construction so that the technology remains a guarded company secret.

Tour around testing centre After the presentation we were divided into two groups to see some of the testing and training facilities of the diesel centre. Most new Wärtsilä engines come equipped with an electronic control module and crews have to be trained to use these. That’s why Wärtsilä has set up an extensive engine simulator for training purposes. Here crewmembers are trained to use the new electronic engine control systems.

We also got a brief view of the testing facility of the combustion research. We were shown lots of results on earlier tests and it was very exciting for us to see actual footage of the fuel injection and combustion process.

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We all really enjoyed the visit to Wartslia Winterthur and we would like to thank them for giving this exciting and informational look into their company. 14

At the end of this very exciting and informational day we headed to Friedrichshafen where we had our night-stay and watched the Netherlands football team play the half finals for the World Championship against Uruguay, which they fortunately won. So what was already a nice day, became even better!!!

Written by: Mike Loonstijn

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Wednesday, visit to MTU Friedrichshafen morning of July 7th… 16

Because not everybody noticed that the program was planned an hour earlier as Monday and Tuesday we left the hotel Swanenburg in Friedrichshafen with a small delay. However we made it on time at the gate of the MTU factory. The guide welcomed us and everybody got a headphone. On the way to the factory hall we passed a truck with the biggest engine produced by MTU (9.1MW) which was prepared for transport. The size of this engine was just small enough for transportation on the road during nighttime.

History

First of all we heard a small story about the history of the company. MTU is located in Freidrichshafen, close to the Bodensee. The company was founded in 1909 as “Luftfahrzeug- Motorenbau “ within the “Zeppelin” corporation. After WWI the company started to manufacture car engines under the name of ‘Maybach Motorenbau’. Daimler-Benz acquired the company in 1960 and later merged its aircraft and diesel engine production under the name of MTU Friedrichshafen. The company was paired with Detroit Diesel as Daimler Chrysler's engine division. MTU Friedrichshafen and Detroit Diesel's off- highway business was sold off in the first quarter of 2006 to allow DaimlerChrysler to focus only on motor vehicle manufacture. EQT has used both groups to form a new company, “Tognum”.

The MTU company manufactures high-speed diesel engines. This means speed >1000rpm. The power ranges are from 240kW till 9100kW. The company manufactures diesel engines for trains, ships, military vehicles, farming, mining and construction equipment as well as diesel- generators.

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Factory 17 First of all we walked through the part where the main components of the engines where produced. We saw the cylinder-liners, pistons, connection rods, inlet/outlet-valves etc. All these components are produced by sophisticated machines. Each component has to meet strict requirement as smooth surface, and weight. However the crankshafts where not produced by MTU itself. But were produced by a subcontractor.

After the production part of the factory we had a look at the production lines. All engines where placed at a production line where all components are placed on the engines. There are two production lines. One for the “smaller” engines and one for the bigger ones. The next step of the factory process is the paint job. The engines are prepared for the paint cabins. The customer can ask every color he likes except the color “caterpillar-yellow”. After this we visited the test facility’s at MTU. The engines (NEW and used) are placed in soundproof halls and are tested.

At the end of the tour we walked through the warehouse where engines where ready for transportation.

First of all I would like to thank MTU for their hospitality and the interesting tour. It gave a good impression of the production of the ‘high-tech’ diesel-engines. Furthermore I would like to thank the board of Dispute Vulcanus 2010 for making this possible.

Written by: Kasper de Ruyck Travel report

Wednesday, visit to Zeppelin museum Friedrichshafen afternoon of July 7th… 18

After visiting the MTU site in Friedrichshafen, some people decided to go to the Zeppelin Museum. The reason why Count von Zeppelin decided to build his airships in Friedrichshafen is because of the Bodensee, which provided a floating hangar to build the first prototypes.

Ever since, the small town of Friedrichshafen (pop: 60.000) is marked by the Zeppelins, leaving not only its name on the main street, but is also providing a lot of industry nearby which was originally intended for Zeppelin production. There is MTU which was founded as Luftfahrzeug-Motorenbau which provided engines for Zeppelins, ZF (ZahnradFabrik) Friedrichshafen which provided gear reduction for Zeppelin propellers and Dornier Flugzeugwerke which took over airplane production facilities.

In 1996 the Zeppelin museum opened for public in an old harbor railway building in Bauhaus style. It features a partly 1:1 rebuild of the infamous ‘LZ 129 Hindenburg’. It also gives a general impression about the building technology, life aboard and around a Zeppelin and the engine technology, leaving behind agitated attendants and puzzled professors.

It also features a good impression of the historical impact of the Zeppelins, starting the Zeppelin holding just before the beginning of WWI, they had to give up three of their airships for war purposes. And in the Weimar republic they had to give up two of their ships to the winning allies of the first world war. Finally it was connected to the Nazi party.

With the concept “Technick und Kunst” the zeppelin museum also houses an art collection which consists mainly of local art work like painted Bodensee views but also contemporary art.

Written by: Andries van Wijhe

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Thursday, visit to M.A.N. Augsburg 8th of July… 20

At 09:30 in the morning we left our hostel in Augsburg and headed to MAN Diesel where the head office is situated. All recovering from the night before when we had “celebrated” the elimination of Germany in the World Championship by Spain. As known by everybody there was one ‘race van’, the one of Dirk. I was participating in this van, which means that you had to chain yourself to survive the ride. Once arrived at MAN we had then of course to wait for the other busses. Finally when they also arrived we were all welcomed in the reception hall of MAN.

Worth to mention is the presence of the first diesel engine in the reception hall. In the years 1893-1897 Rudolf Diesel and MAN engineers developed this diesel engine at the Augsburg premises.

At 10:00 Mr. K Deleroi (the vice president) who has been working for MTU before gave an introduction regarding himself and the company. He told that nowadays MAN Diesel & Turbo is one of the world leading suppliers with a share of 50% of the world trade powered by MAN. This is quite interesting to me, because at Tuesday the 6th of July in Wintherthur at the Wärtsilä company they told us that they are also powering 50% of the world trade. What are the other marine engine manufacturers then powering?

Another interesting point to know is that in Augsburg the 4-stroke engines are engineered and thereof the majority is also build in Augsburg. The remaining part is built in India. The 2-stroke engines are only engineered in Copenhagen. Then in Asia licensed companies will build these 2-stroke engines.

Mr. K Deleroi showed us also the financial figures. He told us that MAN already had to close a factory in Manchester due to the financial crisis. But he added that unless the recession it is still going quite good with MAN Diesel. This is due to the fact that they received a Brazilian order to build 20 engines. These engines must be build and run in 1 year.

The active markets of MAN Diesel are among others the navy, offshore, specialized vessels and dual fuel activities.

At 11:00 the presentation continued with the SOx and the NOx emissions. At first the legislation of the SOx was discussed; the SECA’s. Next to the Baltic Sea, North Sea and the English Channel the Coast of the United States and Canada will be a SECA from the year 2012. Travel report

Furthermore the advantages and disadvantages of the available technologies such as EGR (exhaust gas recirculation), SCR (selective catalytic reduction) and scrubbing were discussed. 21

After that gaseous fuels and CO2-reduction were discussed.

At 12:00 Nicolaus Böckhoft continued the presentation with dual fuel engines. He told something about the bore, which has to be increased due to a lower bmep of DF-engines. He told also something about the pilot fuel arrangement, gas leakages and different operation modes such as HFO, MDO, gas and HFO/gas.

Furthermore he also discussed that homogenous combustion results in lower NOx-emissions when using gas.

Interesting to see was the CFD-simulation showing an optimization in a gas inlet system of an engine. The optimization consisted of an added gas pipe in the inlet system. This pipe, which leads the gas in was constructed to avoid that some gas remained in the inlet system. By applying the gas pipe Mr. Böckholt showed by means of a CFD-simulation that there was no remaining gas in the inlet system any more.

At 13:00 we had lunch which consisted of a 3 course menu with different possibilities. As the rest of the day this was perfectly

organised.

After lunch we had a conducted tour in the huge factory of MAN. The factory consists of a number of sections. The guide showed us the most interesting sections. He started in a sort of meeting hall. Here 2 engines were situated with open cross-sections.

The other halls where we were guided were the halls where they completed the engines, the hall of the turbo machinery, the hall of the valves and the pistons, the hall of the injection parts and the testing hall. Also worth to note is that the injection parts of MAN are build in Augsburg and not licensed to other manufacturers.

After the conducted tour we get a MAN-sweater and a picture was taken of Mr. K Deleroi together with the Vulcanus-group. From the picture we stepped into the van and went back to the hostel. I think at full speed……..

Written by: Michiel Drijver

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Friday, journey back to Delft 9th of July… 23

The last day had arrived and started again with a lot of sunshine. A good start for our journey homeward bound!

As the night before we started in the Übernacht Hostel in Augsburg.

Before we left we had breakfast and we packed our luggage ready for departure.

We left at a quarter to nine, a few minutes after Dirk, and we tried to find the fastest route with one navigation system. And we had to say that one system works easier than two!

After two hours we were hungry and we discussed the possibility to make a stop for a lunch. But as there was someone who would not leave the hotelkitchen messy, and therefore picked up all the bread that lasted and as he shared it with us and the hunger was gone for quite some time.

However later that afternoon we stopped for lunch. At the parking area we stepped out and were totally surprised about the temperature, 35 degrees! We did not notice that during the trip! As a farewell to Germany we had a good tasting German sausage. After that we started for the last leg in the direction of the Netherlands. Unfortunately that last part was not completely free of traffic jams.

At about three o’clock we passed the border near Venlo and we reduced speed for the last part of our trip. At a quarter past five we arrived at the Delft University premises. And miraculously we arrived as first! We had beaten driver Dirk in our last opportunity. Only after ten minutes Dirk arrived as well. So also the mini diesel engines fulfilled their job.

In Delft everybody said goodbye to his or her fellow travellers and then everybody left in his or her own direction. All tired of a very instructive and very nice week!!

But as you may know there were three vans, and we are still waiting for the last one…

Written by: Stef van den Bergh Travel report

Sponsors The last page is reserved for our sponsors. It is thanks to them that we could organize this study tour. 24 Please take a look at the companies and organizations that made this studytour possible.

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