Kongsberg Maritime has won contracts worth approximately 300 MNOK (about $32 million) to equip three adventure cruise ships, with a fourth to follow. Built by WestSea Viana Shipyard in Portugal and destined
SEPTEMBER 4, 2018 — Rolls-Royce today unveiled ELegance – a completely new podded propulsion system designed to meet market demand for smaller, more compact units. The ELegance pods – one with an
APRIL 5, 2018 — RAD-Power, Beaconsfield, Quebec Canada, has been named a new manufacturer’s representative for the Eastern and Central regions of Canada including the Atlantic provinces of Newfoundland, Nova Scotia, Prince
DECEMBER 18, 2017 — Optimizing performance, reducing fuel consumption, and improving profitability for ATB, tug, and workboat operators is more important than ever. Founded in 1972, Nautican engineers and manufactures hydrodynamic solutions
MARCH 13, 2017— Earlier this month, propulsion specialist Reintjes GmbH opened a new branch office in Paraguay as part of its effort to expand its presence in the Latin American vessel market.
Vessel operators are still very much focused on reducing fuel consumption and lowering emissions. Collaboration early on in the design of a new vessel and its construction between the vessel owner, naval architects, shipbuilders, and propulsion manufacturers can payoff in optimizing the vessel’s hull, reducing costs of construction, and lowering operational costs during a vessel’s lifetime.
“We work with naval architects early in the design process to help optimize the propulsion system, looking to meet all design requirements while minimizing the size and horsepower of the system,” says Elizabeth Boyd, PE, President, Nautican Research & Development Ltd. Boyd says collaboration early in the design phase “can result in significant savings because if the horsepower can be reduced due to efficiency gains, it can lead to size reductions in not just the horsepower and propellers, but also everything that goes along with it—shafts, bearings, etc.—sometimes it can even mean meeting the requirements with a smaller boat. We can quickly show performance and full system configuration for different sizes, allowing the naval architect to explore options very quickly.”
Nautican’s foundation was built on efficiency. More than 40 years ago, company founder Josip Gruzling pioneered the use of hydrofoils to increase the efficiency of tugs and barges. Today, Nautican engineers and manufactures hydrodynamic solutions, including patented Integrated Propulsion Units, High efficiency nozzles and propellers, high aspect ratio triple rudders, pre-swirl stators, and also hydralift skegs for barges. It says independent tests show that its propulsion system solutions increase power and maneuverability, while significantly reducing fuel use and maintenance needs.
One of the Nautican’s latest projects is fabricating the first two sets of 104-inch nozzle units for the 120 ft Kirby Offshore Marine line haul tugs under construction at Nichols Brothers Boat Builders, Whidbey Island, WA.
According to Boyd, initially nozzle development was done using both Computational Fluid Dynamics (CFD) and physical testing in a cavitation tunnel and towing tank. “However,” she says, “our CFD efforts now are focused more on integration with the hull form. For these boats, CFD was not used as the design was already well developed and fairly straight-forward as far as placing the nozzles.”
The designer of the ABS Class tugs is Jensen Maritime, Crowley Maritime Corp.’s Seattle-based naval architecture and marine engineering company.
Each of the two tugboats will be equipped with two Caterpillar 3516C main engines, rated at 2,447 hp at 1,600 rev/min. Reintjes reduction gears, supplied by Karl Senner, LLC, Kenner, LA, will turn two Nautican fixed-pitch propellers with fixed nozzles. Other equipment onboard the tugs will include two C7.1 Caterpillar generators for electrical service, one TESD-34 Markey tow winch, one CEW-60 Markey electric capstan and one Smith Berger Town Pin.
“Kirby owns many boats with Nautican systems, but most of these have been ATBs (Articulated Tug Barge units) to date,” says Boyd. “We worked recently with Nichols on a pair of Kirby 10,000 hp ATB tugs—this project went very well and these vessels are performing exceptionally well in service.”
Nautican designed larger 120 inch nozzle units for another tug for Dunlap Towing. “Dunlap is a Nautican repeat customer,” says Boyd. The new tug, says Boyd is a new design, based on the Phyllis Dunlap, but “fully rethought and redesigned by Hockema Whalen.”
The 5,000 hp, twin-screw tug Phyllis Dunlap was built in 2001 by Hansen Boat Company, Everett, WA.
“Dunlap has been a great customer to work with—they are very involved in all aspects of the design and equipment selection and are very knowledgeable, providing some really useful feedback about performance over the years in their very demanding runs to Hawaii and Alaska.”
Wärtsilä Transverse Thruster
Earlier this year, Wärtsilä expanded its transverse thruster series with the addition of the Wärtsilä WTT-40, with a 4,000 kW power level and a 3,400 mm diameter controllable pitch propeller. While Wärtsilä has designed and built customized transverse thrusters as powerful as 5,500 kW, the WTT-40 and others in the WTT range address customer needs for high power transverse thrusters for bow and stern applications.
Development work on the Wärtsilä WTT-40 began in 2015 with an eye on targeting cruise ships, large OSVs and offshore construction vessels. The high power level is particularly important for the harbor maneuvering and docking of large ships, and for dynamic positioning of offshore vessels working in heavy sea conditions.
Because of its maximum power of 4,000 kW, shipyards and cruise vessel designers have the option of using three WTT-40 thrusters instead of four smaller ones. This translates into a more efficient vessel design with less space required for the transverse thrusters. It also allows thrusters to be installed closer to the bow where they are more effective.
Wärtsilä’s extensive experience with propeller design and tunnel optimizations using CFD analysis, ensures an optimal solution when it comes to propulsion performance, efficiency, and the minimization of noise and vibration.
Another benefit of the Wärtsilä WTT-40 is its integrated hydraulics, which save machinery room space and installation and commissioning time at the shipyard.
Innovative ship propulsion systems made by RENK
Military vessels such as patrol boats, corvettes, and frigates looking for “silent running” might well be interested in the Renk Advanced Electric Drive AED. The new drive from the Augsburg, Germany, plant offers a number of special advantages for shipbuilders, says Renk. The propulsion system is a real alternative to the heavy, space consuming electric motors that are rotating at propeller speed.
Modern power electronics allow the use of high-speed motors in combination with an efficient gearbox. The Renk AED combines electric motor and gearbox on one joint frame. Built on soft elastic mounts and equipped with a highly elastic propulsion coupling an incomparably silent operation is possible. The water-jacket of the water-cooled electric motor as well as the double helical reduction gear add to extremely low noise operation.
A modularized lightweight
Thanks to the compact design as well as the low height the preassembled unit is quickly installed with minimum space requirements. Additionally there is a considerable weight advantage. The drive weights around 40% less than a conventional direct drive motor. By comparison, the Renk AED weighs only 23 tons instead of the 35 tons of a direct drive motor of the same power.
Suitable for fixed pitch propellers as well as controllable pitch propellers the drive speed can be flexibly adjusted to the respective propeller requirements. The propulsion systems is built modularly and can be delivered in four sizes from 1.4 to 6 MW. For uses where the requirements are between sizes RENK simply adjusts the capacity of the bigger engine. In this way the complete range of capacities can be covered individually and economically. The motors work with low or mid ranged voltage and are designed –depending on size- for propeller revolutions of 190-450 rev/min.
Investing in new production & testing facilities
Besides pouring millions of dollars into research and development, marine propulsion manufacturers are also investing in new production and testing facilities. Earlier this year, Renk opened one of the largest and most modern test facilities in Europe for gear units at its headquarters in Augsburg. Whether for the shipbuilding, automobile or industrial sector: The multifunctional test facility is especially suitable for the testing of prototypes or special equipment. Renk will not only test its own special gearboxes and propulsion systems, but also those of other propulsion systems or propulsion component manufacturers. The test facility allows for a power capacity of up to 12 MW at 10 revolutions per minute and can take a torque of up to 11 million Nm.
Just this past June, Rolls-Royce Marine unveiled plans for a EURO 57 million plan to upgrade its azimuth thruster plant in Rauma, Finland, and consolidate its thruster assembly and testing to one site.
Rauma produces a wide range of mechanical azimuth thrusters for use on a wide range of applications including semi-submersible drilling rigs and drillships, tugs and offshore vessels. Rauma also produces thrusters for specialist vessels such as icebreakers and polar research ships.
Mikael Makinen, Rolls-Royce, President – Marine, says, “Our azimuth thrusters are one of our most important products, providing mission critical power and propulsion for some of the largest floating objects on the planet. To be able to make this significant investment in Rauma not only prepares us for future growth in this market, but is a vote of confidence in the capability and expertise of our people.””
Azimuthing thrusters rotate through 360 degrees, providing propulsion and maneuverability without the need for a rudder. The largest and most powerful thrusters from Rauma are the ARC type which power icebreakers including the Finnish vessel Fennica. They are among the largest products produced by Rolls-Royce and can each weigh up to 190 tonnes, providing 7.5Mw of power.
Two of the world’s largest floating structures are powered by another range of thrusters produced in Rauma, UUC underwater mountable thrusters:
The heavylift vessel Pioneering Spirit, owned by Allseas, which is used for decommissioning oil platforms, has13 UUC thrusters; and Shell’s Prelude, the world’s first floating LNG production facility, will feature three large UUC thrusters, for position keeping. The thrusters are installed in a novel arrangement that allows them to be removed and maintained within the ship.
The work to transform Rauma will begin immediately and is due for completion in 2020. The investment will include installation of a crane capable of lifting 200 tons, and at least six factory acceptance test rigs. Offices and IT systems will also be refurbished.
Over the years, the use of azimuth thruster has changed the way operators do business. The increased maneuverability and efficiency gains allow tug operators to do more with the same installed power. Added maneuverability can also play a role in improving safety during certain operations. With more than 50 years of developing and manufacturing azimuth thrusters, Rolls-Royce has learned a lot about the specific propulsion requirements of different types of ships and floating structures. Working close with the customers has been a key element of the success.
Steerable azimuth thrusters have come a long way since the first one went into service in 1965. With just 80 hp of thrust it was installed on a mud hopper barge in Finland to make it self-propelled. The first azimuth units specifically designed for inland waterway applications were delivered in 1976. They powered a series of three-river push boats built in Holland and are still operating today.
With the aid of modern computer-based design tools and a detailed understanding of hydrodynamics, Rolls-Royce is continuously developing and improving its thruster product range. The current product portfolio covers a power range of 300 to 14,000 hp.
The benefits of Azimuth thrusters on a towboat
With an azimuth thruster the full thrust can be applied in any direction through the full 360 degrees and significantly improve the maneuverability and braking force of the vessel. In performance tests it has been shown that the braking forces produced are nearly 1.5 times those of the conventional towboat, over the whole speed range. This increase in braking force reduces both the distance and the time needed to stop a barge train.
For shallow draft operations, the normal requirement is to fit 2 azimuth units, and it is not unusual to have towboat designs with a triple azimuth thruster propulsion arrangement.
Azimuth thrusters also significantly increase flanking forces, which help operators safely navigate through the most difficult bends of the river. On a conventional towboat, flanking rudders and reverse thrust are normally used to produce the necessary flanking forces. By using azimuth thrusters the transverse force can be maximized and is approximately twice the maximum side force produced by a conventional towboat at all measured speeds, plus there is the benefit of greater braking forces. Maximum flanking forces produced can be up to 4 times that of the conventional towboat with equal braking force.
How Azimuth thruster help in Brazil
Brazil is a country traversed by many rivers, the main one being the Amazon. There are 11 main inland waterways with a total length of some 39,000 miles although only approximately 8,000 miles are regularly used. These waterways are used to transport agricultural commodities such as grain and fertilizer, as well as mineral goods to the coast.
Amaggi Navegação a subsidiary of Amaggi Exportação e Importação Ltda. is one of the operators working in the region who has moved to azimuth thrusters to propel their vessels. They have been operating on these waterways for over 20 years and now have over 30 tugs equipped with azimuth thruster propulsion. Units in their fleet include a range of Rolls-Royce thrusters from our smaller US 105 model to our larger US 255’s.
Amaggi Navegacao operate on the Madeira and Amazones rivers where they are involved in the transportation of grain and soya to and from local processing plants. The move away from conventional towboat design has enabled them to increase the size of barge trains, which is due to increased turning and stopping capacity at full load.
Open prope
llers are used for the majority of these thruster applications due to the amount of debris in the rivers. The trend outside the Amazon is to fit azimuth thrusters with nozzles and thereby maximize thrust.
The future of Azimuth thrusters
Thruster technology continues to develop. The latest is the introduction of gearless electric drive through the application of permanent magnet (PM) rim drive technology, where the motor surrounds the propeller as a slim ring. The rotor is integral with the propeller and carries a series of permanent magnets. As the magnetic fields interact, the propeller turns. Tunnel thrusters and azimuth thrusters utilizing this technology are now available from Rolls-Royce. The compact and efficient tunnel thruster unit is easy to install and power output is increased by around 25% for the same propeller size. It is a good example of the possibilities that lie ahead.
This technology has now been applied to the azimuth thruster by Rolls-Royce, and the first PM development thrusters rated at 670 hp were installed on the research vessel R/V Gunnerus in March 2015. Nozzle shape can be selected to suit individual applications, but since Gunnerus requires pull for towing trawl and other gear, the nozzle is optimized for bollard pull and speed to match the vessel’s requirements. The installation is compact with only the slip ring unit and the variable frequency steering motors inside the hull.
Before the installation, the vessel had a conventional diesel electric propulsion system consisting of frequency converters, induction motors, gears and shaft with nozzle propeller. Testing to date has demonstrated an improvement in propulsive efficiency and bollard pull with a reduction of air and structure borne noise and vibration.
MARCH 21, 2016 — Maersk Line A/S has selected Wärtsilä Nacos Platinum integrated navigation, automation, and propulsion control systems for 27 new container vessels under construction at shipyards in China and South
MARCH 4, 2016 —A joint research project carried out by Wärtsilä and City University London has succeeded in identifying the specific design parameters that create the risk of “singing” propellers. “Singing” is
FEBRUARY 16, 2016—With more and more towboat operators seriously considering incorporating Z-drive propulsion, Thrustmaster of Texas, Houston, TX, has signed a service agreement with McGinnis Inc. – National Maintenance & Repair that