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Americas Offshore Support Journal

Conference, 2015

Yrjar Garshol

VP Marketing, Commercial Marine

Our global business

AEROSPACE

AEROSPACE LAND & SEA

LAND & SEA

ROLLS-ROYCE BETTER POWER FOR A CHANGING WORLD

POWER SYSTEMS

NUCLEAR MARINE CIVIL

AEROSPACE DEFENCE

AEROSPACE

Land & Sea division overview

MARINE

• Leading supplier of ship designs, power and propulsion systems, deck machinery and through-life support services

• Global leader in integration of complex mission-critical systems for commercial and defence vessels

• Environmental solutions

ROLLS-ROYCEPOWER SYSTEMS

• Specialist in piston engines, propulsion and distributed energy systems and injection systems

• Engines drive ships, heavy land rail and defence vehicles and operate industrial facilities

• Energy systems generate emergency, base and peak load power

NUCLEAR

• Supplies products and expertise into half of the world’s operating nuclear reactors

• World-leader in safety Instrumentation & Control

• Plant lifetime management services

• Design and manufacture of high integrity nuclear systems and components

Marine

A world leader in vessel design, the integration of complex systems and the supply and support of

power and propulsion equipment.

• Clean, efficient, and smart systems

• 4,000 customers worldwide,

including 70 navies• Equipment installed on more

than 25,000 vessels• MT30 – World’s most powerful

in-service gas turbine on major

US, UK and Korean programmes

• No. 1 for pure gas marine engines

• No. 1 for underwater mountable

thrusters

SERVICESNAVAL

FINANCIAL DATA FY2014:

ORDER BOOK

£1,567m

UNDERLYING REVENUE

£ 1,709m

UNDERLYING PROFIT

£ 138m

OFFSHORE

COMMERCIAL

MARINE

MERCHANT

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Marine highlights

• World’s largest rim-driven permanent magnet thrusters

(2 x 500kW) onboard MS “Gunnerus”

• Installation of the Unified Bridge on PSV “Stril Luna”

• 12 UUC thrusters on the world’s largest ship

“Pioneering Spirit” (length 382m, breadth 124m)

• Rolls-Royce established as a leader at the forefront of ship intelligence

• Powered the world´s longest journey at sea by LNG with “Kvitbjorn” from Nor Lines

Commercial marineLong experience in system integration and ship design

The benchmark of the offshore oil & gas

industry

• Almost 800 UT designs in operation or

under contract

• Well positioned as oil and gas

exploration and production continues to

move into deeper waters

• Delivering the widest range of products

in the marine industry

Solutions for the cargo, passenger and tug

boat market

• Achieving optimised through-life costs for

customers whilst enabling compliance

with increasing environmental

requirements

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Services

• Our focus is preventing downtime

and loss of operation for our customers

• We provide conventional services,provision of spare parts, equipment repair, overhaul and

exchange programmes and upgrades

• Several upgrades offers improves

the vessel´s performance and efficiency

• Innovative new services, such as the condition monitoring, are helping to further reduce vessel downtime and provide operators with additional service options.

• Our support philosophy is a recognition that customers have different and often unique requirements based on their fleet operations

Professional service, every port, every day

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Customer product training

• As product experts, we can provide a crew with the knowledge of how to get the best economic and environmental value out of

equipment and systems

• Our product training ensures crew are equipped to operate mission critical systems safely and

efficiently in the broadest range of operational and maintenance scenarios

• Courses are structured to provide

theoretical and practical experience, as well as simulator time to ensure crews operate safely and efficiently

Sharing our knowledge

Global service and support network

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Permanent Magnet Technology

Why Permanent Magnet (PM) Technology?

� No energy is used for excitation of rotor

� Higher efficiency over entire

speed range

� Low heat generation in the machine components

� Best candidate for applications where fuel save is important

1. EFFICIENCY

Machine Efficiency

� Permanent rotor magnetic field

� Simple construction

� Robust candidate for high reliability applications

� Best candidate for integrated product

2. SIMPLICITY

Machine Configuration

� High torque density machine

� 50 % more compact than asynchronous machine

� Slim stator and rotor due to

high pole design

� Strong dynamic performance (synchronization rotor - stator

� Best candidate where space is valued in the application)

3. COMPACTNESS

Machine size and weight

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Why PM Technology for Thrusters? 13

Efficiency CompactnessRobustness(Simplicity)

Asynchronous induction motor max

(max efficiency is 96%)

Oil filled, geared

thruster unit

+

Integrated synchronous permanent magnet machine

(efficiency is above 97% . Higher for partial loads)

Why PM Technology for Thrusters? 14

Efficiency CompactnessRobustness(Simplicity)

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0%

10%

20%

30%

40%

50%

60%

70%

80%

90%

100%

10% 20% 30% 40% 50% 60% 70% 80% 90% 100%

Prop. curve, Operating profile & Efficiency

Operation time

TT Async w Gear

PM TT

Propeller Power

16%12% 9%

Propeller SpeedOperating hours/year: 4000

Energy consumption/year:

Asynch w/gear 1015400 kWh

PMTT 943400 kWh

Energy saved (kWh/year): 72004 kWh

Energy cost 0,808 NOK/kWh

Reduction in fuel cost for 4 PMTT2000

NOK/year 250 000

NOK/lifetime 7 500 000

12% average efficient

improvement

Eff

icie

ncy

, P

rop

. P

ow

er

& O

pe

rati

on

Tim

e

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Why PM Technology for Thrusters?

Efficiency CompactnessRobustness(Simplicity)

Pitch system

Mechanical

transmission line

+

1 moving part (propeller)

Steering gear with improved classic design

Multiple moving parts

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Why PM Technology for Thrusters?

Efficiency CompactnessRobustness(Simplicity)

3,1m

>4,6m

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Why PM Technology for Thrusters

Efficiency CompactnessRobustness(Simplicity)

>4,6m

Inside: 1,3M

Hull and Nozzle:

3,6m

All in 1 room

Location & footprint in vessel

THRUSTTHRUST

Technology demonstration phase19

2001 - 2009

• 50 kW test unit

• 800 kW technology demonstrator

• “Shaftless design” – rotor spins on

circumferential bearings

• AHTS “Olympic Octopus”, 2006-2009

• Installation in stern, next to TT2000, 883 kW

Industrialization phase 20

2010 - 2015

• Revised design, central shaft design

• Hydrodynamic analysis iterations

• Assembly cell and production system

• Quay test rig for full scale testing

• Reintroduced as stern thruster for “Olympic Octopus” 2012 – currently 4000 hours and no maintenance needed.

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Lessons

learnt

Electromagnetic

design

Hull integration

design

Motor sealing system

Hydrodynamic performance

Multi-discipline teamwork!

Hydrodynamics Electromagnetic

Mechanical ManufacturingShip DesignControl Systems

El. Power System

Materials

Manufacturing to scale

Bearing system design

Removed: Rudder with steering gearNozzle with propellerShaftlineGearElectrical motorFrequency converterBridge control system

Installed:•PMazm including steering gear•Lubrication systems•Helicon- control system•Frequency Converter•HEMOS

R/V Gunnerus, built 2006

Propulsion system : 2x500kW, 440V 60Hz

“Classic diesel electric “

Length: 31,25m

Breath: 9,6m

PM Azimuth, installed on R/V Gunnerus

Design and in-house testing500 kW azimuth thruster driven by a PM motor placed inside

the nozzle.

Mechanical strength is 1000kW.

Nozzle have space for a 1000kW PM motor.

Reuse elements from PMTunnel thruster.

Helicon-X control system,

RR PES Frequency converters.

HEMOS data acquisition system,

Design and production: 2012 to Nov 2014

FAT. Nov-Dec- 2014

Delivered Dec-14

Seatrail: March-April-15

Power vs. speed before / after PMAZM retrofit

• Comparison of power consumption .

• The results, when corrected for increased displacement, indicate significant power savings:

8.8 kn ; 13 % Saving

10.5 kn ; 11 % Saving

11.5 kn ; 7 % Saving

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Product design & features

Type PMTT1600 PMTT2000 PMAZM 1900

Power (Max) 1000 kW 1600 kW 1000kW

Propeller

diameter1600 mm 2000 mm 1900 mm

Electrical eff. 97,5% 97,7% 97%

RPM (Max) 338 277 ~209

- +100% RPM~6 sec

or as wanted

~6 sec

or as wanted

~6 sec

or as wanted

VGP Compliant Yes Yes Yes

Terminal box

Rotor Stator Motor house Stays Inlet rings

• Robust “H-frame”-construction,

no shaft dynamics

• Oil for circulation only,

very low volumes

• Designed for Under Water

Installation (UWI)

• Power source: • Active Front End (AFE), alternatively

• 12 (or 18/24) pulse drives

PM technology explained

Permanent Magnet synchronous motor

• Sealed, submerged stator

• Rotor with permanent magnets

• 690 V

Frequency controlled

• AFE or 12 pulse VFD

• Overload protection built into drive

• Sensorless, closed loop control

No mechanical transmission line

• Monoblock fixed pitch propeller integrated in rotor

• Fixed, non-rotating shaft

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Noise and Vibration – “the human ear”27

5 dB

less measured noise....

Noise and Vibration – “the human ear”

50%

less perceived noise

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Noise measurements – ”Olympic Octopus”

4-8 dB Airborne noise

Structure borne noise 6-12 dB

Noise emitted to sea 5-6 dB

Measurements conducted by DNV, April 2013

Life Cycle Cost

• Compared with conventional tunnel

thruster, 50% less maintenance cost

is expected

• The electrical motor is always

included

� Plug Play agreement

� PM motor requires no maintenance

� Less wear, 1 rotating part

� High energy efficiency

� Plug Play agreement

� PM motor requires no maintenance

� Less wear, 1 rotating part

� High energy efficiency

Future priorities

Larger size PM Azimuth thrusters � Main propulsion

� Technology demonstrator project ongoing

� Manufacturability1

Larger size tunnel thrusters � Market demand for larger tunnel thrusters

� Manufacturability2

Auxilary thrusters� Designwork

� Manufacturability3

Permanent Magnet driven Thrusters

Efficient CompactRobust

Cruise liner, 1xPMTT2000 - 1,6 MW

Pipelayer, 1xPMTT2000 - 1,6 MW

Research vessel 2xPM AZM 1900 - 0,5 MW

OCV vessel 2xPMTT2000 - 1,6 MW

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Trusted to Deliver Excellence

Thank you