Pentti Häkkinen Ship auxiliaries.11.2 Wärtsilä New Professionals 3.-7.11.2008 Automation and Control System purpose Collect and process information, Execute.

Pentti Häkkinen Ship auxiliaries.11.2W’ärtsilä New Professionals 3.-7.11.2008

Automation and Control System

purposeCollect and process information,

Execute control actions automatically or as decision support system. locationCabling and workstations through all ship. Computers in the engine room, heavy duty local control terminals also in engine rooms.

main componentsComputers and work stations. Electric and optical cables with routers.

design problemsExpensive system, cabling and testing time consuming. Subsystem compatibility problems. Rapid development brings unmature solutions. Finding safe and remote location for cables and routers.

operation problemsMany software related problems. Updating management is critical. Operator skills need constant improvement and better operator interfaces. Systems influence on ship safety.


Main Switchboard and Starter boards

purposeMain switchboard is backbone of electric system, including control and

monitoring functions. Starter boards control large electric motors. locationMain switchboard close to generators in control room (or adjacent space). Due to safety reasons often divided and placed in two switchboard rooms. Other switchboards seldom in engine room. Centralised starter boards in control room or engine room.

main componentsMain switchboard

design problemsMain switchboard length, up to 14 meter. Big cables & high ventilation demand increase space problems.Emergency conditions -arching, short circuits.

operation problemsSeldom systematic problems.


Main Switchboard and Starter boards

Main switchboard in large ferry engine control room


Emergency Generator and Switchboard

purposeTo supply and distribute electric for vital consumers when power plant is not available. Capacity and operation regulated by Class and SOLAS

main componentsEmergency diesel generator with automatic start located above main deck. Access from open deck, self-contained plant. Emergency cells located above main deck. Supply power after main voltage loss, until emergency generator operates.Sufficient alone in some small cargo ships. Emergency switchboard, located near the power source. Sections:

400V ES1 feeds fire pump, bilge pump, steering gear and other emergency consumers

240V ES2 feeds navigation instruments, fed by ES1 240V ES3 feeds alarm system, emergency & navigation lights,

fed by ES2 or cells

operation problemsStarting failures of emergency generator / emergency fire pump


Main Switchboard and Starter boards Main switchboard for 2 generator ship - total length 9 meter

Normal cubicle height is 2300. Free 300 mm space above and 400 mm below the floor plates required. Cubicle breadth is 600 or 800 mm

Medium voltage (>1 kV) switchboard is abt. 20 % longer. Cubicles 800 or 1000 mm

Separate starter boards: cubicle (600 mm) for 1 … 3 motors.

Add 1 cubicle for each generator. 2 cubicle if main switchboard is divided in halves. 3 …4 cubicles and transition piece if halves installed in separate rooms.

Starters & Shore GEN 1 GEN 2 Shore Starters & 220 V Section Feeders Supply P Supply SB Feeders

To Emerg. board Bustie To 220V Section


Generator and Switchboard Location

Cargo Main Transformers Automation control room switchboard board

Main Control Cargo pump Desk converters

Emergency diesel generator and switchboard



Shaft generator

3 diesel generators on level 9000 mm



Overhaul of a 1600 kVA shaft generator after bearing failure

Vulkan RaTo-type shaft generator coupling


Steam and Feed water System

purposeGenerate and convey thermal energy to consumers Water steam is practical. Alternatives are thermal oil and (for MDO ships only) hot water

locationMain components often in main engine room instead of dedicated spaces. Insulated pipes are lead to consumers through all ship.

main componentsNormally two oil fired boilers and exhaust gas boiler for each main engine. Water tanks and pump assemblies

design problemsHigh capacity boilers and exhaust gas boilers (including overhaul space) cause space problems in passenger ships. Pumps location on low level can also be difficult

operation problemsFeed water related problems Exhaust gas boiler fouling and soot fires


Typical Steam and Feed Water System

Steam to consumers

Mixing does not allow too cold water in boiler

Oil fire boiler(auxiliary boiler)

Feed water pumps

Preheating section

Evaporation section

Circulation pumps

Condensate tank Feed water tank

Return from consumers

Cooling coil

Gas outlet temperature 180oC

SW cooled dumping condenser to handle excess steam


Steam and Feed Water System Capacity

Most ships never use all oil fired boiler capacity. Large boilers in crude oil / black products tankers. Exhaust gas boilers operate dry, use dumping condenser or by-pass.Calculate for each consumer group, see table. 1000 kg steam = 2260 MJ

heat consumer 20 MWicebreaker

2000 pass.car ferry

45000 tdwtanker

cargo oil heating MJ/h 57000HFO storage tanks 600 1700 600HFO treatment plant 2000 2000 750Domestic water 30 2500 20Accommodation heating 1000 19000 2900Engine room heating 1900 15000 3000Fresh water generation - 2000 300Total 5500 42200 64750Steam demand kg/h 2430 18670 28570Oil fired boilers kg/h 1 * 2500 2 * 9000 2 * 14000Exhaust gas boilerskg/h

4 * 1000 4 * 1500 1 * 4000


Oil Fired Boiler Dimensions

Steam collecting space

Steamcapacity kg/h

Heightmm

Widthmm

Mass drykg

1000 3400 1400 33501500 3600 1600 46002000 4000 1700 55003000 4400 2000 75006000 5300 2300 13000

12000 5800 4000 19000

Finned water tubes inside the some tubes

Furnace

Brickwork


Steam Boiler and Feed Water Pump Location

Oil fired boilers Exhaust gas boiler Surplus steam Feed water condenser pumps

Feed water tank


Fire Protection

To activate fire alarm and permit early and efficient fire extinguishing. Ship divided in machinery spaces, cargo space, accommodation (each with multiple fire zones). Fire water system required in all ships. Needed also for cooling of structures. Number and capacity of pumps according to rules. Secondary system is always required.

Carbon dioxide: all fires, efficient in enclosed space, lethal, testing difficult

Water fog: newcomer, all fires, non-toxic, complicated plant, testing easy

Halon: efficient, mildly toxic, banned due to ozone layer depleting effect

Foam: various foams for various purposes, difficult after cleaning(Powder)

Total flooding (Space) extinguishers Local extinguishersLocal compulsory in existing pax vessel by October 2005

Manual release Automatic release


Fresh water systems

purposeTo distillate fresh water from brine utilising waste heat. When waste heat is not sufficient, steam from oil fired boilers is used. To filter and treat water for safe utilisation as technical or potable water.

To store pressurised hot and cold water for consumers. locationLarge multistage units with sea water pumps located in dedicated rooms. Water tanks distributed in various compartments. Cargo ships the small evaporators and hydrophores in main engine room.

main componentsMultistage units & water tanks in cruise liners. Otherwise small components. Reverse osmosis units: small, demand high pumping power, 300 ppm salt.

design problemsLarge evaporator size and high energy consumption. More stages mean low heat consumption but increase cost and dimensions.

operation problemsEvaporator maintenance, bacteria contamination would be disaster.


Fresh water systems

Multistage evaporator Fresh water system

Land connections Port and Sb

Evaporator

Mineralisation

Chlorination

Technical water

Filter Hydrophore

UV unit

Hot Heater Cold water water

Transfer pump

Storage tanks

Dimensions

Watercapacity t/d

Stages L x B x H m Masskg

25 1 1.4x1.8x1.8 160050 1 1.5x2.0x1.8 2000

200 4 7.2x2.3x2.8 13000600 6 12x3.2x3.0 38000

Note that single stage units require double length space for opening

Number ofstages

Heat demandkWh/m3

1 6502 3803 2704 1906 130


Overhaul space

Important overhaul itemsMain and aux. engine piston Turbocharger rotorCharge air cooler insertsMain and big end bearingsClutch and coupling elementsGenerator rotorsPropeller and intermediate shaftsExhaust gas boiler insertsLarge sea water pumpsFeed water pumpsPipe systems, especially HFO, SW

Service space must be providedCentrifuge purifiersFuel injectorsFuel oil booster unit Sea water filtersPiping accessories

Make sure that floor plate and platforms are reinforced for heavy items!


Material transport routes

Material transport to workshop and storages

Main engine large spare parts Auxiliary engine pistonLarge valvesScrew pumpsPump impellersTools

Transport to/from land Main engine large spare parts Large pumpsPipe, bar and plate material

Generator rotorPropeller and intermediate shaft (holes cut in bulkhead may be accepted but no any major component dismantling)

Make sure that floor plate and platforms are reinforced for heavy items!


Overhaul and Material Transport

Service lift and hatch on main deck

Traverse crane above main engine

Lift rail above each genset, leading to ME traverse crane reach area

Engine Engineer store workshop

(Port) Heavy main engine spare parts secured

Aft thruster motor and shaft generator rotor (Port) overhaul is foreseen

Pentti Häkkinen Ship auxiliaries.11.2 Wärtsilä New Professionals 3.-7.11.2008 Automation and Control System purpose Collect and process information, Execute.

Documents

emergency switchboard

switchboard slide

main deck

main engine room

switchboard purpose

switchboard rooms

kv switchboard

wrtsil new professionals