WBTP and SOX Scrubber Retrofit Presentation sname

Engineering Excellencefor your Business

22ND February 2018, Athens Greece

Steps of the Study

1 Week

Initiation of the project Maker of BWTS has been selected

For Sele

ction of B

WTS Mak

er

2-3 Weeks

Feasibility Study

1 Week

Duration 2-3 Weeks

Maker 1 Maker 2

One final selected Maker or Short list of two Makers

On-Board Inspection

Retrofit Time Framework

Phase 1: Basic Engineering

1 Week 3-4 Weeks 3 Weeks 8 Weeks

Phase 2: Verification of Installation Area Phase 3: Detailed Engineering Phase 4: Approval Package &Retrofit Specification*

WBTP Area Match

Preparation of On-board inspection

Preparation of Preliminary PID

Preliminary Pressure Losses Calculations

3D Laser Scanning

Post Processing Point Cloud

3D Virtual Installationof WBTP

Preparation of Final PID

Preparation of Final Wiring Drawings

Final Pressure Losses Calculation

3D Modelling of SelectedAreas - Equipment

Preparation of 3D piping Diagram – Isometric Drawings

Preparation of Class required Drawings

Class Approval Follow Up

Isometric Drawings

MTO

Cable Spec

Supports Drawings

* Depends on required time by Classification Society for approval procedure

Total abt. 12-16 Weeks

The Study

LIABILITY

Maker??Engineering Company??Shipyard??

RETROFIT STUDY

CONSULTING COMPANY TECHNICAL DEPARTMENT OF OWNERSMAKER

Turn Key SolutionMay Absorb the Cost of the Engineering Study

Appoint the study to a Consultant

CONS. COMPANY 1 CONS. COMPANY 3 CONS. COMPANY 2

SHIPYARD

Phase 1 – Basic Engineering

• Engine Room Arrangement• Steering Gear Arrangement• General Arrangement• Pump Room Arrangement• Engine Casing Arrangement• Available Plot Plans

• PID of Ballast System E/R and Hull Part• PID of Bilge System• PID of Compressed Air, Fresh/Sea Water System• Available Piping Arrangement Drawings

Required Data By the COMPANY Model of WBTP will be selected 1

Arrangement and Piping Drawings from 82k DWT Bulk Carrier

1x Ballast Pumps Capacity (One Common Syst.)2x Ballast Pump Capacity (One Common Syst.)1x BWTP for each Pump

Phase 1 – Basic Engineering

Possible Area of Installation of WBTP will be marked Arrangement Drawings will be updated in line with WBTP Equipment layout(s)

2

2x1000m3/h WBP

FilterTRO-N Unit

TRO Sampling Unit

C2E Units

Preliminary PID of Ballast/Bilge3

Preliminary Pressure Losses Calculation for Ballast System4

• Ballast Pipe Pressure Losses• Ballasting and De-ballasting

Rates

Filter

C2E Units

3D Laser Scanning Technique to Point Cloud

3D Laser Scanning – Verification of Installation Area

Sample Engine Room Scanning Positions

• Laser beam is deflected by mirrors to scan the surrounding area and objects• Immediate production of a cloud of measured points (point cloud) with additional

color information for each point (x,y,z,i) or (x,y,z,r,g,b)• Several scanning positions which need registration• Post processing of produced point clouds, combining on single file• Minimize time on board for inspection

Virtual Engine Room available for OFFICE USE

Reduction of Cost and Time


Registration

Scan no.1 on E/R Lower Floor Scan No.2 on E/R Lower Floor

Consider 360o Covering Consider 360o Covering

Alignment and Position of scan from each scanning position to the correct location. Keep in mind that in enclose spaces GPS is turned off which could have been used for reference.

82K DWT Bulk Carrier Engine Room and Steering Gear Room (Point Cloud)

Complete Registered Point Cloud Database – Grey ScaleA


• Maximum 2-3 Days Attendance by two Engineers

• Identification and verification of potential installation areas

• 3D Laser Scanning of potential installation area

• Identification and verification of pipes of interest

• Identification and verification of electric connections and

automation system

115K DWT Tankers Pump Room(Point Cloud)

Complete Registered Point Cloud Database – ColoredB


• Maximum 2-3 Days Attendance by two Engineers

• Identification and verification of potential installation areas

• 3D Laser Scanning of potential installation area

• Identification and verification of pipes of interest

• Identification and verification of electric connections and

automation system

3D Laser Scanner by and


Specification

• Small and compact design (dimensions 24x20x10cm - weight5.0kg) makes it the smaller scanner ever built

• Ideal for extremely fast and accurate indoor and outdoor scans, ranging from 0.6 m to 130 m, measuring up to 976.000 points/secwith accuracy better than ± 2mm.

EX-plosion Environment

Focus3D

Imager 5006EX

Option 1

Use of Explosion Proof Laser Scanner for explosionenvironment such as pump room, Upper Deck where part ofWBTP equipment may be installed

Option 2

Use of conventional Laser Scanner

Scanning should perform during dry docking after allnecessary precautions has been made:

a. Piping Gas freeb. Space gas measurementsc. Modification of Gas sampling deviced. Portable measurements devices during scanning


EX-plosion Environment

Focus3D

Imager 5006EXProblems

1. Limited availability worldwide for leasing

2. Heavy equipment

Scanner 30kg

Portable 3leg Stand 12kg

3. EX Certification for specific type of vessel

4. Slower scanning time

5. Expensive for leasing

6. More expensive the insurance of the ex-proof scanner

7. Leasing cost around 10.000€ -15.000€ per week


Common questions for the scanning are:

Accuracy Preparation CostDeliverables

1 2 3 4


Accuracy (of What????)

Accuracy of the scanning2/3mm @ 100m

Actually less than 1mm inside E/R or Pump Room

Accuracy of the registration2/3mm from scan position to scan position

Depends on the

post processing software

the operator of the scanner during scanning

post processing engineer expertise

Accuracy of the measurementDepends on the registration and on the operator of the viewer

Hint: Always request together the point cloud deliverable and the

report of the post processing software at the end of the

registration. Whatever is less than 2/3mm in 3-axis and more than

0.1o-0.5o angle is unacceptable

12

3


Preparation / Precaution (as applicable)

Preparations1. Area(s) to be clean and tidy2. No loose equipment to be in way of area(s) to be scanned3. No work or repairs or survey to be performed in the area(s) to be

scanned4. Engine room and pump room floor covers/grating to be removed

by the crew, according to the scanner operator’s instructions5. Pump room ventilation to be in operation at max power during 3D

scanning6. Personal gas meter to be provided to scanner operators (two for

operators and one for the scanner)7. Gas meter to be installed in several locations in pump room and

upper/s deck during 3d scanning 8. Cargo lines inside pump room to be stripped9. Pump room bilges to be clean10. Gas sampling unit to be in operation. System interval to be set to

minimum rate.

1Precautions

1. No crew to be present in the off limit area(s) during scanning2. Instructions by the scanner operators and sup. Engineer(s) or

officer in charge shall be strictly followed3. Off limit areas(s) will be marked accordingly, markings to be

respected, not violated and not removed4. Direct eye contact to the scanner lens to be avoided due to danger

of the eye sight5. Contact/removal/change of location of the reference spheres or

checkered tables is strictly prohibited6. Works inducing vibrations in the vicinity of the scanner location

not to be performed7. Scanner and its supports not to be touched by any unauthorized

personnel 8. Sup. Engineer(s) or Officer in charge to order immediate stop of

the 3D scanning in case of gas sampling unit alarm (high gas concentration)

2


Deliverable(s)

Which area(s) will be scanned?????Dedicated areas identified for the retrofit

Or all the engine room

Or/and pump room

Or in addition the engine casing

Or in addition engine casing/funnel external

Or in addition cargo area/tanks (Framo type Tankers)

Database and File TypeComplete registered database of all the scanned areas

Or multiple database for each scanned area without

connection between scanned areas (i.e. ER and Pump

room)

Raw data, FLS, Recap,E57, xyz, other

Something more than scan??Assessment on the available space for installation

New Pipes routing

Identification of the connection to existing piping

Identification of the spare MCCB for electric connection

Hint: Point cloud will be Owner’s/Operator’s property or property

of the Company who performed the scan ?

12

3


COST (for non Ex proof??)

Define what you pay forFor the Scanning

For the Scanning and the Post Processing

For Scanning and the Post Processing in which file format

For Scanning and the Post Processing and the report of the scanning

1000$ block

fee per vessel

6500$-8000$

block fee per

vessel

400-1000$ / (day and operator)

3D Laser Scanning – Feasibility of BWTS Installation

Point Cloud 3D Model by the Maker

Piping Routing by Retrofit Engineer+ + = Assessment of

Equipment Installation and Pipe Routing

Proposal of Different Scenarios of Installation and Pipe Routing

,

Scenario A Scenario B

Installation Scenarios of the Main Equipment of the BWTS






,

Scenario A Scenario BRouting Scenarios of the Main Pipes






,

Scenario A Scenario BMaintenance Space Consideration


Always request Pressure Loss Calculationsfor the worst case scenario of ballastoperation.

New Operation profile for the ballast pumpand clear indication of the ballast flowreduction resulting in increasing of ballastingtime. This may define the final routing of thepipes.

Phase 3 – Detailed Engineering

1

Class

Drawings

Revision

Calculations 3D Modeling

1 2 3 4


1Class Drawing Revision1

Final Drawings (Depends on Classification Society Requirements)

• Revised Diagram of Ballast System

• Revised Diagram of Bilge System

• Revised Wiring Diagram of Power System

• Revised Wiring Diagram of Alarm System

• Equipment Supports Structural Drawings

• Machinery Arrangement / Pump Rom Arrangement

• Arrangement of Electrical Equipment

• Ballast Management Plan

Tricky Part

• Response time of Makers for submitting the general drawings

• Piping System Drawings may be changed due to actual arrangement of the

valves and Pipes

• Operation of the ballasting System should not interfere by the installation of

the new equipment

• Specification of the valves and pipes on specific spool pieces should be re-

assessed for hydraulic shock and for the design pressure rating

• Existing valves and pumps/equipment should be safeguarded by the

increased pressure

• Auxiliary equipment of BWTS have special arrangement requirements

• Corrosion of pipes and Spool Piece

• APT ballasting


1Calculations2

Final Calculations

• Final Calculation of Pressure losses and new flow rates of Ballast

Piping System

• Final Calculation of Pressure losses and new flow rates of Cooling or

Heating System

• Final Calculation of Power Consumption

• Amendment of Electric Power Balance

• New Electric Operation Profile to be defined

• New Ballasting/De-Ballasting rates/time to be defined

• Equipment Supports Structural Strength calculations (*if required)

Tricky Part

• Short Circuit calculations (not available drawing to the class, not complete defined variables during the calculations, needs software for the calculation with certification of IEC61363

• Actual Operation profile of D/Gs

• Calculation of MSB Bus Bar and Branches if required

• Actual needs of vessel operation

• Flow rate of auxiliary equipment (i.e. cooler, heater)


1Calculations2

Short Circuit Calculation Pressure Drop Calculation


13D Modeling3Tricky Part

• Detail Level of 3D Design• Pipes >DN50 • Only Main Pipes• Foundations• In-detail foundations• Cables• Length of Cables

• Purpose of 3D Design• Arrangement Assessment• Prefabrication of foundation and main

pipes• Complete prefabrication• Prefabrication and pre-installation by the

crew and technicians prior DD• Quotation by Shipyard for the retrofit

• Is it necessary for you?????

Final Outcome is the Technical Specification for the retrofit

• Arrangement drawings for the new equipment• Isometric drawings for piping with MTO• Fabrication drawings for piping• Cables length for installation prior dry docking• Construction drawings for foundations• MTO (piping, structure, cabling)


1Technical Specification and drawings3



Assembly Drawing Connection(s) Drawing



Tricky Part

• Spool Pieces• Final adjustment on board (field weld for flanges, extra length)• Pipe fitting compatible with selected shipyard and Maker

Isometric Drawing with MTO Fabrication Drawing



Pipe Proposed Support


1Material Lists3

Pipe MTO

Steel Beam MTOCabling MTO


1Material Lists3

Steel Beam MTO


1Material Lists3Pipe MTO


1Material Lists3Cabling MTO

1 Week

Retrofits of SOx Scrubbers Source: Clarkson

Maker 13%

Maker 223%

Maker 39%

Maker 45%

Maker 53%

Maker 64%Maker 7

3%

Maker 810%

Maker 96%

Maker 1015%

Maker 118%

222 Ships (July 17)

1 Week

New Orders with SOx Scrubber Source: Clarkson

Maker 110% Maker 2

3%

Maker 33%

Maker 41%

Maker 549%

Maker 63%

Maker 711%

Maker 811%

Maker 99%

75 SHIPS (JULY 17)

Prediction for Global Marine Use

1 Week

Source: BPSource: Shell

Requirements to be integrated

1 Week

Shipping Company

Scrubber Vendor ClassM/E, G/E & Boilers’

Makers

Demanding Multi Task Design

Vendor’s requirements and

guidelines

Other Engineering

Class Rules and Guidelines

Makers requirements &

guidelines

Ø Arrangement &installation details inline with goodmarine practices

Ø RedundancyØ Operation FlexibilityØ Maintenance issuesØ Minimize repair

workØ Calculations/design

not being Classitems

Ø Sets the timeduration for theretrofitting

Ø Requiresminimum timein the repairShipyard

Ø Minimize Costsand operationheadaches

Steps of the Study

1 Week

Keep in mind

1 WeekØ Shipping Company should define the design Exhaust Gas flow (kg/hr), Exhaust Gas inlet temperature, SW alkalinity and temperature.

Ø Maximum design temperature to be defined and cover with sufficient margin the actual most demanding case (i.e. G/Es at low loads during Tropical Conditions)

Ø Clearly indicate compliance with vessel’s Class Rules. It is highly recommended to assess Vendor’s offered scope of supply with Class Rules prior to confirming order. In case of non compliance in an aspect, operation restrictions could be required and/or additional equipment/cost.

Ø In case of Dry Running, the unrestricted duration of dry running and the maximum allowable exhaust gas temperature should be defined.

Ø Auxiliaries’ Specification (e.g. Dampers, valves, pumps) to be assessedØ Guarantee terms should be assessed. Guarantee based on running hours to be requested.Ø In case of Boiler(s) connection, special consideration together with Boiler’s Maker should be given in respect

to the back pressure. In-line forced fan shall be required in case of retrofitting projects.Ø In case of Auxiliary Boiler(s) connection, special consideration should be given in respect to the IGS

operation.

Offered Technical Specification

Keep in mind

1 Week ØFunnel/Casing modificationØBends of large diameter exhaust gas piping ØMaintenance (e.g. exhaust gas piping bellows)ØSW washing overboard discharge(s) locationØRadars Blind ZonesØFunnel MarkØVibrationsØAccessØE/R Ventilation ductsØECR & ECC arrangementØ Funnel/Casing aesthetics

Arrangement Aspects

Keep in mind

1 WeekØ Exhaust gas piping back pressure Calculations. The challenge is on the modelling of exhaust gasmixing.

Ø Exhaust Gas Piping Thermal Deflection CalculationsØ Exhaust Gas Piping stress calculations iwo tricky arrangementsØ Tower’s Foundation and Bracing strength calculations. Dynamic loads should be consideredØ Short Circuit CalculationsØ Assessment of the S/C and Main Sea Cross Line sizeØ CFD Analysis of the SW washing overboard dischargeØ Assessment of the installed Fixed Fire Fighting CapacityØ Electric Load AnalysisØ Stability assessmentØ Equipment Number assessment

Calculations

Keep in mind

1 WeekØ In case of In-Line scrubber the necessity of the exhaust gas by-passØ Redundancy Issues (e.g. 1x100% SW Washing pump or 2x100% SW Washing pumps)Ø Approval of Vendors DrawingsØ Safety issues in respect to M/E, G/Es & Boilers OperationØ Inducing operation restrictions by the Class should be avoidedØ E/R Unmanned Operation (i.e. interface with AMS)Ø Safety Devices and Alarm DevicesØ Class should define the Rules’ Edition that is applicable for the SOx Scrubber

Retrofitting.

Class Aspects

Keep in mind

1 WeekØ Makers, Class, Shipyard & Shipping company are involved. Tests’

Scheme should be prepared and mutually agreed well in advanceØ M/E, G/Es & Boilers’ transient operation profiles should be checkedØ Tests with the vessel chartered may be required. Ø HFO with 3.5% sulphur should be availableØ Exhaust gas back pressure measurements should be carried out in line

with M/E Makers GuidelinesØ SW water temperature and alkalinity to be close to the design values

On Board Testing

Keep in mind

InnovativeTop

Management Decision

Demanding Engineering Several Parties

Involved

About 6 months for

having a concluded

design

Limited Time for the

installation

Affects the operation of

M/E, G/Es and Boiler(s)

operation

Technical Department should

be pro-active. At least detailed

feasibility study should be carried

out and conclusion on a Maker, if

practicable

WBTP and SOX Scrubber Retrofit Presentation sname

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