henrik bacher elomatic
TRANSCRIPT
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C O N S U L T I N G & E N G I N E E R I N G
How to Choose and Integrate Best
System that Fulfills Your Requirements
Henrik BachrVP Consulting & Engineering
Elomatic Oy
www.elomatic.com
4th Ballast Water Management Summit
11-12.4 2011, Amsterdam, The Netherlands
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C O N S U L T I N G & E N G I N E E R I N G
Objectives of the presentation
General overview of BW treatment technologies, system selection and
installation considerations
Focus on retrofits;
- the choise of system is more challenging in retrofits
- many key considerations are applicable for NBs just as well.
- in NBs however this is one system out of several to be designed and
installed, the degrees of freedom are higher, shipyard responsibility
Neutral approach, no supplier preference nor technology ranking
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C O N S U L T I N G & E N G I N E E R I N G
Marine Mechanicaldesign
Processindustry
CADMATIC3D
software
A multidisciplinaryconsultancy &engineering company
Finnish, privatelyowned
Abt. 650 employees
11 Offices in 5countries
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C O N S U L T I N G & E N G I N E E R I N G
Marine
From conceptual development to detail design of all disciplines
From cruise vessels to working craft
From newbuildings to conversions and
retrofits
Our clients include shipowners,
operators shipyards, equipment
suppliers and many more in the
maritime cluster
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C O N S U L T I N G & E N G I N E E R I N G
Contents
1. General considerations and challenges
2. BWT technology
3. Vessel specific considerations and
indicators
4. The process of choosing solutions
5. The role of design & engineering
6. Installation aspects
7. Conclusions
1. General considerations and challenges
2. BWT technology
3. Vessel specific considerations and
indicators
4. The process of choosing solutions
5. The role of design & engineering
6. Installation aspects
7. Conclusions
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C O N S U L T I N G & E N G I N E E R I N G
Why do we need BW treatment? What is behind the
convention ?
S.Saesmaa/ Finnish Environmental Institute
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C O N S U L T I N G & E N G I N E E R I N G
General considerations and challenges
Each ship is unique and should be dealt with as such
This is a must; investments are inevitable (return on investments?)What makes the BW treatment system topic so special
Amount of ships to be dealt with; up to 70.000
Number of questions mark concerning the convention and
interpreatations + regional/local requirements (US)
Technology, installation and operational challenges
This is no rocket science
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C O N S U L T I N G & E N G I N E E R I N G
General considerations and challenges
Special vessels; practical solutions for a.o. barges, semisubmersibles, dredgers
etc. are needed
Industry tendency; leave the retrofit to the last minute to be sure of what to doand a (false) expectation for a broader competition and thus lower prices
Critical issues;
- equipment supply
- engineering capacity
- installation capacity
Abt. 20 retrofits/day during the coming years
Ships to be converted
Year 2012 2013 2014 2015 2016 2017 2018 2019No of ships 1700 3000 3000 6000 6000 16000 14000 14000
Tankers > 100.000 tdw existing abt. 1400
NB's abt. 500
Bulkers > 100.000 tdw existing abt. 750
NB's abt. 700
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C O N S U L T I N G & E N G I N E E R I N G
The BWM Convention Regulation B-3
Built BW m 2005 2006 2007 2008 2009 2010 2011 2012 2013 2014 2015 2016
< 2009 1500-
5000
< 2009 5000
2009 5000
2012 >5000
D1/D2D1/D2 D2D2
D1/D2D1/D2 D2D2
D2D2
D1/D2D1/D2 D2D2
D2D2
Source TraFi
D-1 standard; BW exchange
D-2 standard; BW treatment
First intermediate or renewal survey after theanniversary date of delivery of ship, whichever first
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C O N S U L T I N G & E N G I N E E R I N G
BW treatment technology
Abt. 50 manufacturers of BW technologies on the market
11 systems are approved under the IMO G8 (no active substances)
27 systems have basic approval according to G9 (active substances)
18 systems have final G9 approval
Type approval by flag administration 12 systems at least
Additional 3 applications for basic and final approval which could not be handled
in MEPC 61 will be handled in MEPC 62 (July 11 -15, 2011) and additional
applications and approvals are expected during 2011
MEPC 62 will focus on ships with BW capacity > 5000 m3
MEPC 62 will approve guidelines for other methods as well as upscaling of
systems
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C O N S U L T I N G & E N G I N E E R I N G
BW treatment technology
- Mechanical filtration (28)
- Hydrocyclone (3)
- Chemical enchantment (coagulation/flocculation)
- Mechanical filtration (28)
- Hydrocyclone (3)
- Chemical enchantment (coagulation/flocculation)
Disinfection
Physical pretreatment and solid/liquid separation
Residual controlResidual control
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C O N S U L T I N G & E N G I N E E R I N G
BW treatment technologySource IMO
G9
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C O N S U L T I N G & E N G I N E E R I N G
Source IMO
G9
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C O N S U L T I N G & E N G I N E E R I N G
Source IMO
+ RWO CleanBallast, Unitor BWTS
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C O N S U L T I N G & E N G I N E E R I N G
BW treatment technology
Combinations of technologies are also adopted
Supplier focus on various capacity ranges (100 7000 m3/h, even >10.000m3/h)
Serial or parallel installation to increase capacity
Modular solutions/distributed equipment
Operational modes
- ballasting, ballasting & discharging, filter bypass on deballast, during voyage
- neutralization of chemicals prior discharge
Operational costs- major factor for most systems; power (large consumers are eg. elctrolytic and
advanced oxidation processes)
- chemical systems; chemicals
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C O N S U L T I N G & E N G I N E E R I N G
Installations and experience
Abt. 350 systems sold/installed
Abt. 200 vessels, mostly NBs
Retrofits limited, abt. 10 % of the sold/installed systems
Retrofits include ao. car carriers, bulkers, tankers, passenger vessels,
container vessels, special craft
Several systems (suppliers) have accumulated running hours and someexperience have been gained
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C O N S U L T I N G & E N G I N E E R I N G
Which BWT solution for my ship ?
The ideal objective: max benefit to lowest
(overall) cost
Each ship is individual
There exists no standardized general best
solution
A thorough system comparison and
consequence analysis is the starting point
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C O N S U L T I N G & E N G I N E E R I N G
General considerations in selecting BWT solutions
Ship type & size
Tanker , bulker, container, car
carrier , passenger etc.
Ship type & size
Tanker , bulker, container, car
carrier , passenger etc. Trading pattern, routes
World wide traffic, short sea shipping,regular line service, operating areas
(seas)
Trading pattern, routes
World wide traffic, short sea shipping,regular line service, operating areas
(seas)
Operational aspects
Reliability, safety, servicerequirements
Operational aspects
Reliability, safety, servicerequirements
Economical aspectsInitial capex, operational costs
Economical aspectsInitial capex, operational costs
Technical aspects
Physical, material
Technical aspects
Physical, material
Performance, ballast needs
Capacity and flow rate requirements
Performance, ballast needs
Capacity and flow rate requirements
Compliance!
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C O N S U L T I N G & E N G I N E E R I N G
Technical/operational considerations and key aspects
Performance considerations
Required time to be effective
Performance considerations
Required time to be effectiveCapacity
Ballast pumping and treatment rates
Capacity
Ballast pumping and treatment rates
Maintenance
Crew training and workload
Accessibility
Maintenance
Crew training and workload
Accessibility
Power requirements
Additional need, existing capacity
Power requirements
Additional need, existing capacity
Technology
Footprint , weight, gas safeequipment
Technology
Footprint , weight, gas safeequipment
Existing BW system
No of systems, integration
Existing BW system
No of systems, integration
Installation aspects
Alterations in existing structures
Component location flexibility
Installation aspects
Alterations in existing structures
Component location flexibility
Corrosion
Tanks, material selection
Corrosion
Tanks, material selection
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C O N S U L T I N G & E N G I N E E R I N G
Technical issues
Examples of technical matters needed to be worked out in close cooperation
between all parties
- bypass options (emergency if the BWT inoperable)
- backflushing filters
- vent lines from the BWT system (termination on deck or in the engine
room spaces depending on gas to be ventilated)
- ballast pump capacity and powering requirement (av. 30 40 % increasein demand)
- use of alternative piping materials (class issue)
- corrosion risks (material issues, coatings)
- sampling ports- Safe Return to Port issues
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C O N S U L T I N G & E N G I N E E R I N G
Technical issues cont.
Special tanker considerations
- fore and aft BW systems
- pipes from BW tanks adjacent to cargo tanks not into the engine room- on deck installations currently under discussion (pump head requirements
increase)
- limitations of electrical components in the cargo pump room (except for
explosion free lights) pre/ post 2007, zone 1 (IEC 60092 502)- possibility to re-class hazardous area from pre to post 2007 standards
- BW pump capacity, 10.000 m3/h or more
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C O N S U L T I N G & E N G I N E E R I N G
Automation, control and monitoring
- BWT system requirements
- automation and control equipment for monitoring and adjusting treatmantdosages and/or intencities
- a continuous self-monitoring function during the period in which the system
is in operation
- recording of functioning and failure + data storage- alarms
- audible and visual alarm signals in all stations from which BW
operations are controlled in case of system failure
- visual alarm whenever the BWT systemis in operation for purposes ofcleaning, calibration, or repair
- by pass alarm in case of emergency bass pass activation
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C O N S U L T I N G & E N G I N E E R I N G
Automation, control and monitoring
- control system location options
- local panel- ECR
- CCR
- integration to existing automation and/or BW systems,
- operation and control
- alarms
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C O N S U L T I N G & E N G I N E E R I N G
The solution evaluation processScore sheet System A B C D
Operation Principle Filter Filter Filter Electro-
UV UV Cl lysis
Score scale: 0-10,
10 being the best Weight factor
Performance and capacity
Purification
Filter min. particle size (m) 0,1 4 8 6 10Disinfection performance (technology) 0,3 9 9 7 9
Zoo plankton [per/ m3] (limit 10) 0,2 6 8 6 6
Photyplankton [per/ml] (limit 10) 0,2 6 8 6 6
Vibrio Cholerae [per/100ml] (limit 1) 0,1 6 10 6 6
Escherichia col i [per/100ml] (lim it 250) 0,1 6 10 6 6
Intestinal Enterococci [per/100ml]
(limit 100)
0,1 6 10 6 6
Total 7,3 9,7 6,9 7,9
Process
Flow rate per unit and maximum flow 0,5 8 9 7 6
Energy consumption (kw/m3) 0,6 10 5 7 8
Chemical consumption (mg/l) 0,7 10 10 5 10
Pressure loss [bar] 0,5 4 4 7 10
Working pressure 0,1 5 6 6 6
Ex-class 0,3 8 3 7 8
Supply water (l/min) 0,1 8 8 4 8
Total 22,7 18,8 17,8 23,6
Total Technology Subscore 30 28,5 24,7 31,5
Score sheet System A B C D
Operation Principle Filter Filter Filter Electro-
UV UV Cl lysis
Score scale: 0-10,
10 being the best Weight factor
Dimensions and modular izat ion
Size of the 250-334 m3/h u 0,4 7 2 4 7
Footprint of 250-334 m3/h 0,6 7 3 2 1Size for 2000m3/h unit [m3 0,4 8 2 5 8
Footprint of 2000 m3/h uni 0,6 6 3 7 7
Modularization 0,8 7 7 4 5
Weight in operation [kg] 0,1 8 5 6 6
Total Size Subscore 20,2 11,3 12,8 15,4
Total Size Score 8,5 5 6 7
Equipment cost
Equipment cost [] 0,8
Instal lat ion cos t
installation cost 0,5 3 2 3 3
Instal lat ion tim e
installation time 0,3 3 2 2 2
Operational cos ts
operational costs 0,8 6 4 3 8
Reliability
Support network 0,8 8 6 8 4
References 0,6 4 2 3 8
certificate/imo compliance 0,5 5 3 3 5
Total Reliabili ty Subscore 11,3 7,5 9,7 10,5
Total Reliability Score 9 7 7,5 8
Lead tim e
Lead time
TOTAL SCORE 48 36 34 47,5
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C O N S U L T I N G & E N G I N E E R I N G
The retrofit process
Solution & consequenceevaluation, comparisons,preliminary (basic) design
Solution & consequenceevaluation, comparisons,preliminary (basic) design
Supplier selectionSupplier selection
Basic design & eng.Basic design & eng.
PlanningPlanning
InstallationInstallation
Testing &
Commissioning
Testing &
Commissioning
LogisticsLogistics
ProcurementProcurement
General ,
Technical,
Operational
considerations
General ,
Technical,
Operational
considerations
Individual contracts
Turn key (yard or supplier)
EPCM
Individual contracts
Turn key (yard or supplier)
EPCM
Detail designDetail design
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C O N S U L T I N G & E N G I N E E R I N G
The role of design & engineeringA ship specific optimum solution requires a deep cooperation
between shipowner, BWT supplier and the design &
engineering party
The design role include
- basic system arrangement and equipment location
- integration to existing systems and tie in points
- necessary modifications to the existing vessel
- maintenance access as well as installation access and
routes (component size, existing hatches, working openings)
- classification & flag authority issues and approvals- general naval architecture issues
The detail design can commence once all approvals are in
place
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C O N S U L T I N G & E N G I N E E R I N G
The role of design & engineering cont.Only a thorough design can guarantee a
good result; the more you design and plan
the more you will control and influence
(=reduce) costs and avoid surprises.
3D design may be an advantage
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C O N S U L T I N G & E N G I N E E R I N G
Supporting design tools laser scanningWhat is laser scanning?
Measuring method to get 3D data (accuracy 0,1 5 mm)
Point cloud created by laser scanner
Point cloud edited to engineering format as a 3D model
Why laser scanning?
When documentation is poor or only old system drawings
are available
Ensures the present as built status with high accuracy
Creates an ideal basis for the retrofit design
Enables use of todays design tools
Need for ship visits is reduced
Design errors are reduced
New components can be delivered as prefabricated units
Potential to reduce total costs
Laser scanning point cloud
3D Basic model
Retrofit design model
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C O N S U L T I N G & E N G I N E E R I N G
Supporting tools laser scanning cont.
Example of a recent laser scanning raw data (contains also numerical information)
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C O N S U L T I N G & E N G I N E E R I N G
Installation considerationsOut of service - drydocking or alongside
- Justified in combination with a scheduled
drydocking
- When large working/transportation
openings are needed in the hull
- When new hull overboard penetrations are
needed
- Preparatory and finalization work can be
done while in service in order to minimize
down time
- Advantages; infrastructure, logistics, labor
& material in case of surprises
- Disadvantages; loss of earnings (unless
streamlined with a scheduled drydock)
C O N S U L T I N G & E N G I N E E R I N G
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C O N S U L T I N G & E N G I N E E R I N G
Installation cont.In operation
- Possible if a drydock is not needed; several
retrofits carried out prove that
- Requires extensive planning
- A high degree of prefabrication is needed
- Logistics may be a challenge and needs strict
management (depending on trading pattern)- Solutions to enable the minimizing of hot work
- Special solutions should be considered (pipe
couplings etc.)
- The design is in a key position- Disadvantage; poor coverage against
surprises (material, special workforce etc.)
C O N S U L T I N G & E N G I N E E R I N G
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C O N S U L T I N G & E N G I N E E R I N G
Alternatives to ballast solutionsWhy ballast?
Immersion (propeller, bow), trim (optimum running condition, avoid
slamming), load distribution (strength), stability, anti-heeling
Ballast free and alternative designs
- Various concepts have been developed/are under development
- Reduced ballast need (simpler BWT system)- Storm only ballast
- Flow-through designs (VLCC:s)
- Ballast free designs through special hull form
DNV/ Making Waves
C O N S U L T I N G & E N G I N E E R I N G
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C O N S U L T I N G & E N G I N E E R I N G
ConclusionsThe BW convention is expected to enter into force within a reasonable future
There is no general best solution each ship is individual
There is a number of proven technologies on the market
A thorough pre-design/evaluation study pays off
Retrofit installations including logistics needs to be planned in detail with high
priority
Design capacity, equipment supply and installation capacity may become critical
C O N S U L T I N G & E N G I N E E R I N G
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C O N S U L T I N G & E N G I N E E R I N G
Thank you for listening
Q & A