This MAN Is Alpha a Headline This High-performance is a subheadline Naval Propellers
Highest Propeller Performance Reduced Hydroacoustics Increased Flexibility Larger Fuel Savings Lowest Total Cost of Ownership 2 MAN Alpha Naval Propellers
MAN Alpha Naval Propellers Reliable systems tailored to tough demands MAN Diesel & Turbo is proud to present a naval propeller programme, which has been developed on the basis of the industry's state-of-the-art design and optimisation tools combined with the vast experience accumulated from more than 7,000 propellers. A long tradition and a grand heritage with propellers for both commercial marine and military applications date back to the first Alpha design, which was produced in 1902 and patented in 1903. Flexibility for covering efficiently any propulsion power requirement in the 4-40 MW shaft power range is our overall target. The optimised propeller performance from both controllable pitch propeller (CPP), fixed pitch propeller (FPP) and adjustable bolted propeller (ABP) designs with tailored blade configurations contributes to forceful and energy-efficient missions with a reduced impact on the environment. Propeller diameter (mm) 9,000 8,000 7,000 6,000 5,000 4,000 3,000 2,000 1,000 VBS790 VBS720 VBS660 VBS600 VBS860 VBS940 VBS1020 VBS1100 VBS1180 VBS1260 VBS1350 VBS1450 VBS1550 VBS1640 VBS1730 VBS1810 VBS1890 5-bladed naval propellers The MAN Alpha CPP programme offers an excellent coverage of the propulsive demands in the 4-40 MW power bracket. Today, a wide range of naval and patrol vessels are propelled by MAN Alpha propellers ranging from powerful combat frigates, command support vessels and offshore patrol vessels to coastal supply cutters. 0 0 5,000 10,000 15,000 20,000 25,000 30,000 35,000 40,000 Shaft power [kw] MAN Alpha Naval Propellers 3
Increased Propulsive Efficiency Hydrodynamic competences in force For maintaining and developing MAN Diesel & Turbo's position in the propulsion forefront, many resources are invested and the latest advanced design tools including e.g. CFD (Computational Fluid Dynamics), FEM (Finite Element Methods) and Topology Optimisation are deployed. To verify the calculations, MAN Diesel & Turbo cooperates with the world's leading test tanks and research institutes. Hydrodynamic design characteristics Maximised efficiency with due respect to controlled cavitation, pressure impulses, vibration and noise Skew, rake, area-ratio and blade number parameters are all balanced and efficiency-optimised The shape of the hub is flow-optimised and reduced in size resulting in a low drag The flow optimisation includes a streamlined shape of the hub and blade integration As always, the propeller designs are optimised to the individual ship application and mission profile. Operational advantages Increased propeller efficiency is translated into savings via lower fuel consumption, reduced exhaust gas emissions or may be exploited as higher thrust for increased ship speed for a given engine power. Benefits of the MAN Alpha propellers Efficiency increased by up to 6% (Kappel design) Lower propeller-induced pressure impulses Reduced risk of cavitation high blade loading possible for demanding applications. CFD streamlines during operation, showing reduced tip vortex High blade loading simulation reduced root cavitation below 4 MAN Alpha Naval Propellers
Hydrodynamic integration and optimisation The perfectioned layout and hydrodynamic propeller integration are always optimised with the ship's hull and any 'flow-guiding' devices placed before the propeller, e.g. pre-swirl fins and vortex-generators. After the propeller, the optimisation will consider high-efficiency rudders, integrated rudder bulbs, post-swirl fins or similar. According to a recent design study, the combination of a 5-bladed propeller with Kappel blades and fairing cone operating with a rudder with integrated rudder bulb will offer a power saving of up to 9%. MAN Alpha Naval Propellers 5
High Propulsion Performance and Low Noise Innovative Kappel propeller blade designs Multiple MAN Alpha propeller design solutions are available all the way from propellers based on the very advanced and unique Kappel tip fin design to conventional blade designs for both CPP and FPP in 4 and 5-bladed executions. Nature of optimisation parameters Lower speed and larger propeller diameter Larger diameter and blade number optimisation Lower pressure impulses and smaller clearance to the ship's hull offer the deployment of a larger propeller. Kappel design tip fin benefits Tip vortices are formed due to the difference in pressure between the pressure and suction sides of the propeller as the water will move from the region of high pressure to the region of low pressure. The pressure on both sides near the tip will therefore equalise and the efficiency of the tip region will decrease. High efficiency The Kappel propeller minimises the flow over the tip, and the outer region of the Kappel propeller therefore retains high efficiency increasing the total efficiency of the Kappel propeller compared to conventional propellers. Low hydroacoustics In addition to the higher efficiency, especially for highloaded propeller blades, the Kappel designs ensure a reduced noise signature in general. For similar reasons, silent Kappel propellers are also designed for submarine applications with lowest acoustic signatures and surface ships employing stealth technology. Tip vortices conventional versus Kappel. Tip vortices are tubes of circulating water that are formed at the tip as the propeller generates thrust Kappel propeller surface pressure distribution and streamlines 6 MAN Alpha Naval Propellers
Scale model 1:28. A 6.4 metre MAN Alpha fixed pitch propeller with Kappel blades - optimised for a feeder vessel Kappel submarine propellers for silent missions: 8-bladed model propeller test and 7-bladed propeller finished machined MAN Alpha Naval Propellers 7
Reliable CP and FP Propeller Designs Mechanical robustness and safe handling The hubs are designed and optimised with due consideration to the propeller/shaft torque, material properties and weight. The MAN Alpha propeller reliability and durability have always been very high, and the latest generation of CPP and FPP designs follows that philosophy. Mechanical design characteristics Robust approach with ample design margins As standard, the propeller material is specified as G-CuAl10Ni. Other material available upon request Material fatigue levels are calculated for a 30-year lifetime, considering all possible external loadings in service Designed for ice operation according to the newest IACS and FSICR ice class notations Ice loadings include the influence of ice milling on the complete system's torsional response Compact hub/blade root design and low weight ensuring well-balanced load distribution Optimised for reduced material stresses during normal operation and extreme loads Shock resistant component designs analysed and documented to current military standards. Von Mises stresses at blade roots in wake field normal loading Propeller designs strengthened for the highest ice classes 8 MAN Alpha Naval Propellers
More speed and power featured Novel blade and blade foot design advantages: The 'multi-radius-fillet' design reduces the blade weight by approx. 4% and contributes to a higher cavitation inception speed The optimised hub/blade interface allows for higher propulsion power densities. Operational advantages Low wear rates and very long lifetime Higher reliability with few components Reduced bearing loads due to low weight Smaller hub dimensions resulting in high efficiency Large pitching range and great manoeuvrability Increased service and inspection friendliness. MAN Alpha Naval Propellers 9
Plant Competence and Added Customer Value Perfect tools and know-how for integrated solutions COPS a unique layout tool COPS is an abbreviation for Computerised Optimisation of Propulsion Systems. MAN Diesel & Turbo's COPS expert system ensures better and more accurate pre-optimisation of hydrodynamic/mechanical aspects, integrating e.g. statistical data, torsional vibration data of the complete propulsion system including main engine parameters. The propeller range offers excellent coverage The propellers handle outputs from 4,000 to 40,000 kw per shaft. Multiple propeller solutions are available for direct coupled, geared diesel-mechanical, dieselelectric, hybrid and combined propulsion plants. 10 MAN Alpha Naval Propellers
Tailored propeller systems and stern tube concepts: compact and optimised installation dimensions are ensured in consideration of e.g. ships' hull shape, rudder arrangement, engine room, shafting and stern tube equipment. Optionals and special installation requirements MAN Diesel & Turbo masters a vast number of disciplines in relation to optimisation of aftship parameters and special installation requirements, such as: Rudder design interaction Integration to rudder bulbs Guide vanes for wake field improvements Special shaft brake and locking devices De-magnetisation of propeller shafts. Customised stern tube solutions Water lubricated stern tube systems are often selected and tailored for naval propeller installations including our new compact and easy to install water supply units. The optional oil lubricated stern tube systems are adapted to both biodegradable oils and ordinary mineral oils. Switching from one type to the other is possible without any requirements for component changes. MAN Alpha Naval Propellers 11
Robust Hydraulic and Servo Systems CPP manoeuvrability swift and safe A shock resistant hydraulic power unit and an ODF oil distribution unit prepared for flooded compartment operation: the ODF design includes a unique 100% linear feedback system a contact-less ultrasonic design with no use of linkage bars. No wear and no hysteresis in feedback Hydraulic power unit The hydraulic power unit offers high-volume hydraulic modes ensuring optimal 'crash stop' opportunities. ODF oil distribution unit A new, very compact ODF oil distribution unit has been developed for gearbox mounting. A short and very robust unit with 20% fewer parts compared with today's ordinary ODF designs. The installation length has been reduced by 22% for the benefit of very short and compact engine-gear-propeller installations still with the necessary access and service friendliness. Fast propeller blade pitch changes and safe manoeuvres are possible due to a 28% higher pitching torque for a given propeller hub size compared to previous designs. Full feathering: CPPs with FF option offer a special manoeuvre mode with optimal pitch setting for e.g. economical sailing or convoy cruising with one propeller disengaged in full feathering position 12 MAN Alpha Naval Propellers
Shock Excitations, Design Precautions and Testing Calculations and analysis of propeller and shaft system Shock excitations in the shaft lines A complete MAN Alpha propeller system can be designed and documented to any shock requirements. A full shock response analysis is carried out for the complete scope of supply in accordance with current military standards. Full-scale shock testing from underwater explosion This serves to ensure that all mission critical components are designed with ample safety margins against underwater shock inputs. Controlled torsional vibrations An MAN Alpha shafting and propeller system will be optimised, adjusted and documented to ensure safe operation. The optimisation will be done by proper modifications to the main engine tuning, flexible couplings or shaft line dimensions taking the total cost structure of the complete plant into consideration. FEM analysis: propeller hub assembly subjected to simulated shock from underwater explosion Controlled shaft line whirling vibrations The whirling vibrations are generally non-critical for single screw installations, but may cause problems for long and slender shaft lines' characteristics for twin screw vessels. Fully excited, whirling vibrations may lead to critical structural vibrations and shaft bearing and stern tube seal problems. Whirling vibrations may be counteracted by proper layout of the shaft line and its bearings based on analysis and our huge experience with complex propulsion systems. Shafting: struts, bearings and an Inconel clad-welded tail shaft MAN Alpha Naval Propellers 13
Worldwide After-sales Service Logistic support packages and training No compromises From the pool of MAN Diesel & Turbo's selected suppliers and manufacturing partners, we are cooperating with proven and well-established organisations worldwide. To ensure the highest level of safety, availability and continuity, all suppliers are quality-screened, audited and approved via MAN Diesel & Turbo's extensive supplier verification system. Highest MAN standards Like for the extensive and advanced production of MAN Diesel & Turbo's diesel, gas and dual-fuel engines, turbomachinery, gas turbines, steam turbines, compressors and turbochargers including the genuine after-sales spare parts the MAN Alpha propellers are also produced only by high-end foundries and propeller manufacturers. PrimeServ: the MAN Diesel & Turbo service brand PrimeServ offers after-sales service for the entire range of MAN products from spare parts supply, technical service, re-conditioning and retrofit, to engine and propeller maintenance concepts. Logistic packages The PrimeServ organisation's products and services are to a high extent presented as userfriendly kits offering the highest degree of product safety, top quality spare parts and the availability of correct amounts - together with associated 'work card' instructions. PrimeServ Academy training for operational staff PrimeServ Academies are competency centres for product training with the focus on design, operation and maintenance of propulsion engines, GenSets, gearboxes, propellers and remote control systems. 14 MAN Alpha Naval Propellers
PrimeServ's worldwide service support With more than 150 PrimeServ service stations and service partners worldwide, plus a growing network of PrimeServ Academies, the MAN Diesel & Turbo organisation is highly committed to expanding and developing the most efficient and accessible after-sales organisation in the business. Propeller retrofit packages Take advantage of new designs and technology or general product improvements, matching e.g. new requirements or changed operating profiles for your ships. Attractive investments are available with short payback time. For propellers, as well as for engines, gearboxes and control systems PrimeServ provides: Delivery of high-demand spares within 24 hours Fast, reliable and competent customer support Ongoing training and qualification of personnel Global service, open 24/7, 365 days a year. MAN Alpha Naval Propellers 15
All data provided in this document is non-binding. This data serves informational purposes only and is especially not guaranteed in any way. Depending on the subsequent specific individual projects, the relevant data may be subject to changes and will be assessed and determined individually for each project. This will depend on the particular characteristics of each individual project, especially specific site and operational conditions. Copyright MAN Diesel & Turbo. 1510-0201-01ppr Aug 2014 Printed in Denmark MAN Diesel & Turbo Niels Juels Vej 15 9900 Frederikshavn, Denmark Phone +45 96 20 41 00 Fax +45 96 20 40 30 info-frh@mandieselturbo.com www.mandieselturbo.com www.manalpha.com MAN Diesel & Turbo a member of the MAN Group