Henrik Bacher Elomatic

8/10/2019 Henrik Bacher Elomatic

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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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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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Marine Mechanicaldesign

Processindustry

CADMATIC3D

software

A multidisciplinaryconsultancy &engineering company

Finnish, privatelyowned

Abt. 650 employees

11 Offices in 5countries


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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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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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Why do we need BW treatment? What is behind the

convention ?

S.Saesmaa/ Finnish Environmental Institute


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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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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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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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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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- 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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BW treatment technologySource IMO

G9


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Source IMO

G9


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Source IMO

+ RWO CleanBallast, Unitor BWTS


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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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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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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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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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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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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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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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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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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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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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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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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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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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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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Supporting tools laser scanning cont.

Example of a recent laser scanning raw data (contains also numerical information)


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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)



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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.)



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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



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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



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Thank you for listening

Q & A

[email protected]

Documents

Henrik Bacher Elomatic