Alf Kåre Ådnanes Vice President Technology A Concept of Environmentally Friendly Propulsion System ABB Automation Technologies
Facts about ABB arine & Cranes ABB Automation Technologies - 2 900 employees in 19 countries Three centers of excellence: Oil & gas related vessels (Norway) Cruise & ferries (Finland) Crane and harbor systems (Sweden) Two centers of competence Drilling application (Singapore) Domestic market (China) A global partner in supply of electric propulsion, drilling drives, and harbor crane systems arket leader in 5 core vessel segments: Cruise, Ice breakers, Offshore supply vessels, LNG Carriers, and drilling vessels arket leader in crane automation, and crane drive systems
arine system business ain benefit of electric propulsion system ABB Automation Technologies - 3 Safety and reliability with improved manoeuvrability and high redundancy Increased payload through flexible location of machinery components Environmental benefits from lower fuel consumption and emissions High performance in tough ice conditions due to maximum torque at zero speed Better comfort due to reduced vibration and noise Flexible general arrangement and easy installation Reduced lifecycle cost by reduced fuel consumption and maintenance cost
Growing Ship Transportation ABB Automation Technologies - 4
Almost All Vessels with Combustion Engines Engines: Fuels: Slow Speed Heavy Fuel Oil Direct propulsion Cheap(er) High efficiency High efficiency Expensive High Sulphur and NOx Wärtsilä High reliability edium Speed emissions arine Diesel Oil ABB Automation Technologies - 5 Wärtsilä Geared propulsion or electric propulsion Lower efficiency than slow speed Cheaper, lighter High Speed Geared propulsion or electric propulsion Cheaper, lighter Lower efficiency LNG Expensive(r) Lower efficiency than HFO Lower emissions Cheaper fuel, but more expensive installation High efficiency Very Clean Caterpillar
Fuel Consumption and Greenhous Gas Emissions ABB Automation Technologies - 6
Not only a Global, but also a Regional Problem ABB Automation Technologies - 7
SO x and NO x ABB Automation Technologies - 8
Power Generation Distribution - Propulsion Power Distribution and Transmission ABB Automation Technologies - 9
Electric Propulsion Diesel-Generator Set Variable Speed Drives -Transformer - Frequency Converters - otors Electric Power Distribution - ain Switchboard - Distribution Switchboard - Distribution Transformers ABB Automation Technologies - 10 Propulsors and Thrusters
Ten Indicators for Electric Propulsion Requirements and Operational Characteristics Weight Optimized for ice breaking Station Keeping and/or maneuvering Low acoustic noise and vibration Redundancy, availability, and fault integrity High variance in propulsion and/or vessel loads Use of LNG or dual fuel engines Flexibility in design and space utilization ABB Automation Technologies - 11 Low emissions High electric load for ship equipment and process Technology shifts new vessel designs One: Worth to evaluate Two: Often enough Three: Normally enough Four and more: Don t waste time on other solutions
Still niche and Increasing Share of electric propulsion 5,0 4,0 3,0 2,0 1,0 0,0 2003 2004 2005 2006 ABB Automation Technologies - 12 Electric propulsion share in %
WW New-build arket and Type of Ship Dry cargo ships Construction vessels, Cable & Pipe Layers, Offshore DP, Icebreakers Passenger vessels Ore / Bulk / Oil Carriers RO-ROs ROs Bulk carriers ABB Automation Technologies - 13 Container ships Reefers Tankers
Reduce Environmental Footprint ABB Automation Technologies - 14 Reduced activity Acceptable? Optimizing operations Environmental emissions Clean fuel Reduce fuel consumption Reduce emission in any fuel concept Environmental spill Increase availability of propulsion and maneuverability Redundancy and fault tolerance
With Relations to Environmental Footprint: Requirements and Operational Characteristics Weight Optimized for ice breaking Station Keeping and/or maneuvering Low acoustic noise and vibration Redundancy, availability, and fault integrity High variance in propulsion and/or vessel loads Use of LNG or dual fuel engines Flexibility in design and space utilization ABB Automation Technologies - 15 Low emissions High electric load for ship equipment and process Technology shifts new vessel designs
Ship Types ABB Automation Technologies - 16
Ship Types ABB Automation Technologies - 17
Ship Types ABB Automation Technologies - 18
Offshore Support Vessels ABB Automation Technologies - 19
A Variety of Technologies 24-pulse Harmonic filters Zippers Sinusoidal 6-pulse ABB Automation Technologies - 20
Criteria for Design Optimization ABB Automation Technologies - 21 High availability... High reliability... Low operational costs... inimize risk for black-out... Short recovery time after black-out... Quantify short Life time operational support Spare parts Service personnel Upgrades Training Segregate inimize parts count Parallel gen-sets Segregate Protective devices Increase complexity vs. fool-proof Standardization
Simplicity by Advanced Technologies Simple Complex ABB Automation Technologies - 22
OSV: Typical Two-split System Diesel Diesel DP0, DP1, Electric DP2, 6-pulse Electric Generator Generator Diesel DP3, 6-pulse Electric Generator Diesel Electric Generator Electric Power Distribution Electric Power Distribution Electric Power Distribution Electric Power Distribution Filter Electric Electric FCPropulsion FC Propulsion FC FC System System Filter Filter Electric Electric FCPropulsion FC Propulsion FC FC System System Filter ain propulsion Tunnel thruster Retractable thruster Tunnel thruster ain propulsion ain propulsion Tunnel thruster Retractable thruster Tunnel thruster ain propulsion ABB - 19 - Thrusters, Propulsors Thrusters Propulsors ABB - 21 - Thrusters, Propulsors Thrusters Propulsors DP0, DP1, DP2, 12- / 24-pulse DP3, 12- / 24-pulse ABB Automation Technologies - 23 ABB - 20 - FC FC FC FC FC ain propulsion Tunnel thruster Retractable thruster Tunnel thruster ain propulsion ABB - 22 - FC FC FC FC FC ain propulsion Tunnel thruster Retractable thruster Tunnel thruster ain propulsion
Hybrid Solution Aux gen. 1665kW 2000kVA. Pf 0.8 900RP 690V, 60Hz G 3200kVA, pf 0.9 2x3500kW 900RP 1300 kva 2x3500kW 900RP G 3200kVA, pf 0.9 800kVA 3250kVA 3250kVA 800kVA ABB Automation Technologies - 24 450V Distribution Bow Thruster 883kW 1200 RP 2700kW 1200RP 6500kW Az Thruster 1100kW 1200RP 6500kW 2700kW 1200RP Aft Thruster 883kW 1200 RP 450V
Fuel Oil Consumption Large PSV / OSV Electric vs conventional propulsion. Yearly fuel oil consumption for inimized Opex design Electric A vs. B Conventional ABB Automation Technologies - 25 Example: 500kW savings NPV = 4,000,000 in LCC LCC over 12 years; 0.10/kWh incl fuel cost, capital cost and maintenance; 200g/kWh; 5% ROC net
Environment and Emissions NOX EISSIONS (ABSOLUTE) 450 440 430 420 T/YEAR 410 400 390 380 ABB Automation Technologies - 26 370 D-E Azipod propulsion D-E Propulsion Conventional propulsion
The VSD Variable Speed Drive Transformer (Optional) Voltage adaptation Harmonic distortion and EC Frequency Converter VSI Voltage Source Inverters Others FC ABB Automation Technologies - 27 otor Induction Synchronous Other
Drive Technology ap (Indicative) P (kw) 40 000 30 000 27 000 CSI ABB Automation Technologies - 28 otor Power 16 000 10 000 9 000 6 000 5 000 2 000 315 VSI IGBT 690 Cycloconverters VSI IGCT or IGBT 1.0 1.5 1.8 2.4 3.3 4.5 6.0 otor Voltage VSI: Voltage Source Inverters with PW or DTC CSI: Current Source Inverters with Thyristors Cyclo: Direct Converter with Thyristors 6.9 U (kv)
Power Generation Distribution - Propulsion Efficiency: 40% Efficiency: 90% Efficiency: 65% P in P O W E R F L O W P out 3-4% 0% 1-2% 2-3% 3-5% ABB Automation Technologies - 29 P in Efficiency: 80% Generator Switchboard Transformer Frequency converter Electric otor Efficiency: 100% - Aux P out
Facts - or Creative and Speculative Semi-science The main power to the propulsion motors is supplied directly from the generators to the variable speed drives, thereby reducing losses by 10-15% eaning: Reducing losses by 10-15% of 8-12% loss P in P O W E R F L O W P out Or.. in other words ABB Automation Technologies - 30 Decreasing total loss from 76.6% by 0.3% to 76.3% or 1% efficiency increase P in Power losses 3-4% 1-1.5% 2-3% 3-5% Generator Switchboard Transformer Frequency converter Electric otor P out
Driving Forces - Should be: ABB Automation Technologies - 31 Cost efficient building and installation Performance for intended operation Continuous availability to propulsion and station keeping systems inimizing constraints of operations High safety for operations High safety for crew Good working environment for the crew Reduced impact on the external environment, lower emissions Reduced fuel consumption Low maintenance costs Flexibility in design that improves ship utilization Availability to maintenance during the life cycle of the ship Availability to maintenance in the region of operations, world-wide Spare parts availability Remote and on-board support
Case Study: AHTS with DEP ABB Automation Technologies - 32 Demanding Installations High bollard pull requirements Large winch capacity, typically 500 tons Up to 200+ metric tons bollard pull -> more than 15000kW engine power DP Class 1 or 2 Dimensioning Traditional: Obtain bollard pull with minimum building cost Today: Obtain bollard pull, but optimize for life cycle cost Technology Trends ultipurpose use higher DP classes From Diesel echanical Propulsion To Diesel Electrical Propulsion Pure Electrical Hybrid Electrical echanical
AHTS Operating Profile Example Harbor 6 % Anchor Handling 5 % Bollard Pull Condition 1 % DP/Standby LO 32 % Transit Towing 15 % ABB Automation Technologies - 33 DP/Standby HI 16 % Transit Supply 25 %
Diesel echanical 200+ tons Emgc y gen. Aux gen. 440V, 60Hz 99kVA 99kVA ABB Automation Technologies - 34 230V Bow Thruster Port Side propulsion and shaft gen. Stbd Side propulsion and shaft gen. Bow Thruster 230V Distribution
Diesel Electrical 200+ tons Azimuths G_S1 G_S2 G_S3 G_S4 6600V, 60Hz 99kVA 1000kVA -7.5 o +7.5 o 440V Galley 440V Distribution Y Y 1000kVA 440V Distribution ABB Automation Technologies - 35 150kVA 230V Distribution Tunnel Thruster Port side Propulsion Stbd side Propulsion Az Thruster 150kVA 230V Distribution
Hybrid 200+ tons Aux gen. 1665kW 2000kVA. Pf 0.8 900RP 690V, 60Hz G 3200kVA, pf 0.9 2x3500kW 900RP 1300 kva 2x3500kW 900RP G 3200kVA, pf 0.9 800kVA 3250kVA 3250kVA 800kVA ABB Automation Technologies - 36 450V Distribution Bow Thruster 883kW 1200 RP 2700kW 1200RP 6500kW Az Thruster 1100kW 1200RP 6500kW 2700kW 1200RP Aft Thruster 883kW 1200 RP 450V
AHTS Alternative Propulsion Concepts ABB Automation Technologies - 37
Fuel Oil Consumption Hourly Fuel Oil Consumption kg/h Operation Base Case Electric Profile D-ech Propulsion h/year Anchor handling 2280 2295 438 Bollard Pull Condition 2451 2795 88 Transit Towing 1898 2053 1314 Transit Supply 1276 1036 2190 DP/Standby HI 1377 1020 1402 DP/Standby LO 1015 620 2803 Harbor 26 25 526 Total FOC kg/year 11 293 005 9 396 661 Total FOC m.t./year 11 293 9 397 Difference, m.t./year 0 1 896 Total FOC m.t./year Difference, m.t./year 12 000 0 D-ech Electric ABB Automation Technologies - 38 10 000 8 000 6 000 4 000 2 000 0 D-ech Electric 500 1 000 1 500 2 000 2 500
AHTS Concepts A Simple Comparison Diesel echanical Diesel Electrical Azimuth Hybrid Electrical echanical Building Cost 1 3 2 Operational Cost 3 2 2 ABB Automation Technologies - 39 Complexity in Construction Flexibility in Operations 1 3 3 1 3 2
Summary: Ten Indicators for Electric Propulsion Requirements and Operational Characteristics Weight Optimized for ice breaking Station Keeping and/or maneuvering Low acoustic noise and vibration Redundancy, availability and fault integrity High variance in propulsion and/or vessel loads Use of LNG or dual fuel engines Flexibility in design and space utilization ABB Automation Technologies - 40 Low emissions High electric load for ship equipment and process Technology shifts new vessel designs One: Worth to evaluate Two: Often enough Three: Normally enough Four and more: Don t waste time on other solutions
ABB Automation Technologies - 41