Rolls-Royce Marine Deutschland GmbH

In-depth Issue 7 2004 UT 517: Managing coastal zones Integrated submarine rescue system Fine-tuned ducted propellers Innovation from simulation Issue No. 7 2004 Published by Rolls-Royce plc PO Box 2000 Contents Derby DE21 7XX 1 Viewpoint - Dr Saul Lanyado UK 2 News www. rolls-royce.com 6 Simulators stimulate innovation Statements made and opinions 8 Winch up-date expressed do not necessarily reflect those of the publishers. 10 Submarine Rescue Vehicle draws on combined skills P13 12 Zebra battery charged with success MT30 Chosen to Editors: 13 MT30 chosen to power US Littoral Combat Ship option power US LCS Arnfinn Ingjerd Andrew Rice 14 Azipulls fulfil their promise 15 Offshore optimism Designed and produced by: 16 Worldwide support Naval Marine Visual Communications 18 Regenerated frigates begin new life Printed in the UK 19 Control system conversion combines the old and the new If your details have changed or P14 20 Full control - from the comfort of your chair you wish to receive a regular Azipulls fulfil complimentary copy of In-Depth their promise 21 Fast naval vessels favour waterjets please contact our circulation to deliver 22 Waterjets: smallest to largest department for an application form. Fax: +47 70 01 40 05 24 Multi-purpose protectors manage coastal zones Email: marianne.leine@rolls-royce.com 26 Fins fine-tune ducted propeller performance 27 Speed with safety for Finnlines ropax ferries 28 Full rudder range strengthens steering system programme P22 29 Coming alongside speeds up storing at sea New waterjet series builds on 30 Trawler designs target safety success 31 Clean-burning gas engines primed for marine market 32 Contacts Front cover: Simulators are a powerful tool for designing and training, as demonstrated on page 6. Rolls-Royce is a partner in this full scale bridge simulator located in Ålesund, Norway, which can The wide range of marine equipment available from Rolls-Royce is now be set up to represent different ship operating explained in an expanding range of new brochures. The ability to supply scenarios, such as offshore anchor handling. individual items of equipment or turnkey packages with systems designed and manufactured specifically for each vessel is a particular strength of Rolls-Royce. If you would like your own reference copies, please email your address details to Marianne Leine – marianne.leine@rolls-royce.com. Viewpoint At Rolls-Royce, the name inspires us all to do our best to look after Another project which reflects great credit on our people was the challenging our customers – even if we don’t get it right all the time. In this role to provide the £47 million NATO age of e-mail and video conferences it is still important to talk, the submarine rescue system. The article about human factor is more vital than ever before. We recognise this and this project demonstrates the level of hope that as you read this issue of In-Depth you will see that we technical expertise and innovative thinking do talk to our customers, and listen to them available for perhaps the most basic customer support of all – saving lives. I’m More and more shipbuilding is taking place our people have achieved here, bringing in delighted that the Royal Navy, in common in Asia. This is a long-term trend and we have affordable technology that delivers value to with our other customers, continues to place responded by setting up a new sales, service, our customers. its confidence in us. assembly and test facility in Shanghai. We are engaged in many long- Elsewhere we are opening sales and service term projects, and are delighted that offices in Piraeus and Dubai. Our global sales our MT30 gas turbine is leading key US and support network now covers Navy programmes and has successfully 34 countries. In most corners of the Earth, a completed ABS endurance testing, in customer with a problem knows he can get addition to the DNV certification it had hold of someone from Rolls-Royce – we are already achieved. trying hard to improve this aspect of what Rolls-Royce is a support business as 1 we do. well as a manufacturing one and we look When Rolls-Royce bought Vickers in after our engines even when the customer 1999, there were a few people who thought changes. We have played a major role in the Group’s traditional surface ship and refurbishing two UK Royal Navy frigates for submarine business would not gel with the Romanian Navy, working with prime the mainly Nordic commercial business. contractor BAE Systems. Naval marine However, technology transfer is working well support director Sam Cameron says for us and our customers. A good example: inside:“As original supplier of the we have adapted our UT-Design offshore propulsion system it made sense for support vessels for use as coastguard us to take package responsibility for platforms in Norway and France. There are this part of the contract.” also further opportunities in the pollution And thus eight Olympus and control area, which will be covered in future Tyne engines have been given issues. a new lease of life. We are now Our offshore business has been planning to look after them successful over the past three years and is – and also motion control now performing robustly but with reduced systems and deck machinery volumes. Anders Almestad, who runs this – in a through-life support business, is ‘cautiously optimistic’ about the agreement for up to future. He says inside:“We feel that increased 15 years. construction work in 2005 will help to absorb the oversupply of service vessel tonnage and stimulate the demand for new and efficient vessels.” Those vessels will be equipped with our latest technology which includes Azipull thrusters, developed in Ulsteinvik and already setting new standards in vibration and improved course stability. You can read about how Bourbon Tampen benefited from Dr Saul Lanyado retrofitting Azipulls. We are proud of what President Marine IN-DEPTH ISSUE 7 www.rolls-royce.com News Twin Azipulls strengthen 24 hours.

The MT30 marine gas turbine Perfected in the air...to excel at sea Modern, state-of-the-art gas turbine technology for the marine market delivering… • Up to 36MW with a market leading power-to-weight ratio • 80% commonality with aero Trent for high reliability and low ownership costs • Self-contained, single lift package weighing 22 tonnes • > 40% thermal efficiency giving nominal 0.207 kg/kWh specific fuel consumption • Modular design for simplified maintenance • Meets current and anticipated emission requirements The MT30...perfected in the air... to excel at sea The MT30 is the Designed for the 21st century The MT30 brings the very latest aero gas turbine technology to the marine market and gives latest evolution of operators of gas turbine powered vessels efficiency and reliability improvements, with a market leading power-to weight ratio and reduced operating and through-life costs. Designed with 50 to 60 per cent the Rolls-Royce Trent fewer parts than other aeroderative gas turbines in its class, the MT30 has a maximum continuous rating engine family that of 36MW up to ambient temperatures of 26°C, and maintains operating efficiency for powers down to 25MW. The MT30 can be configured for either mechanical or electrical drive. have accumulated more than five Heritage The MT30 shares 80 percent component commonality with its successful aero parent the Trent 800, million flying hours which has now evolved into an engine family of six since its introduction in 1996. It has now amassed more than five million flying hours with nine out of every 10 engines selected for Boeing 777 aircraft, since entry into since its introduction, being the Trent. service in 1996 Capable and affordable From the outset the MT30 has been designed to provide cost efficient propulsion for both commercial and naval applications. Ideal for vessels requiring high power density, it provides the propulsion system designer with increased flexibility in terms of ship layout. Vessel owners can also benefit from Rolls-Royce ‘Total Care’ which provides a menu of tailored support options to cater for individual requirements. MT30 Features Market leading power-to-weight ratio Compact, flexible and responsive power unit Modular construction for lower maintenance costs Excellent fuel economy The 36MW power unit weighs under 7 tonnes Available as a package on an optional baseplate, the engines acoustic enclosure is fitted with automatic fire detection and extinguishing systems ...perfected in the air... to excel at sea The MT30 has Advanced design – proven technology The MT30 can be configured with an axial intake plenum (for funnel installations) or compact rotatable maximum radial intake for machinery space installation and is a twin-spool, high-pressure ratio gas generator. Compact and lightweight, the MT30 features an eight stage variable geometry Intermediate Pressure component Compressor and a six stage high-pressure compressor. The four-stage free power turbine is derived commonality with from the Industrial Trent, with bearings and support based on the WR-21 gas turbine design. Proven components, incorporating the latest blade cooling technologies are used throughout. Key rotating its aero Trent 800 parts are protectively coated for service in the marine environment to reduce maintenance and deliver long service life. parent for high reliability with low The annular combustors are similar to the aero parent and designed to burn commercially available distillate fuel to DMA standard, ensuring the MT30 meets all current and anticipated legislation on ownership costs emissions and smoke. The Engine Management System (EMS) provides fully integrated alarm, monitoring and control functions for the packaged gas turbine, including independent engine overspeed protection. An The MT30 is designed to integral back-up power supply ensures continued safe control should the ships main supply be meet stringent reliability and interrupted. Modern databus technology provides improved reliability through simplified wiring and a reduced number of connectors, with main processors and power supplies located in a cabinet maintainability goals on the outside of the package enclosure. The system is designed for operation in unmanned Aero Trent MT30 Parentage MT30 machinery spaces, control and monitoring provided by remotely mounted dedicated touch screen panels supporting easily interpreted graphics. Alternatively, control functions can be directly integrated into ship level machinery control systems, communicating to the EMS through a dual redundant databus. Lightweight With the gas turbine change unit (including power turbine) weighing just 6,200kg and a total module weight, including enclosure, of 22,000kg (dependent on options) the MT30 offers the best power-to-weight ratio in its class.

The widest range of marine products from a single supplier Gas Turbines Diesels Cable Handling Control/Automation Stabilisers Steering Gear Propulsors/Propellers Azimuth Thrusters Waterjets & Electrical Systems CPP and FPP As the pioneer of aero-derivative gas turbines Four Bergen diesel engine families provide A comprehensive range of high/low pressure With the recent acquisition of VT Controls, Our expertise in fin stabilization and passive Rolls-Royce have long been leaders in the Rolls-Royce is the world leader in the design and Modularized Azimuth thrusters in the Ulstein Rolls-Royce is the world's leading expert in for surface ship propulsion, Rolls-Royce offers powers from 0.9MW-6MW and deliver reliable hydraulic and electric mooring and anchoring Rolls-Royce has added an extensive capability in controlled tank stabilization from the well supply of steering gear and rudders for both manufacture of combat capable propulsion Aquamaster range are available in a variety of waterjet technology. Our Kamewa range of turbines in the 3 - 50MW power range. The power as prime movers or as packaged systems are offered for virtually all commercial electrical power, propulsion, control and known Brown Brothers and Intering product naval and commercial vessels. All products are systems. Bird-Johnson CPPs have been installed standard and retractable designs, with the waterjets is the broadest in the business and Allison AG9140 gas turbine generator set generator sets. Rolls-Royce also manufactures and naval requirements. Products and systems automation. The acquisition compliments the ranges, enables Rolls-Royce to offer combined from the proven Brown Brothers, Tenfjord and on every class of US Navy surface combatant options of open or ducted CP and FP propellers. have been installed in 20 different classes of powers all US Navy DDG-51 destroyers. The under license the well known Crossley Pielstick are from the Rolls-Royce and Rauma Brattvaag™ Rolls-Royce established data management, Frydenbö ranges. fitted with this type of propeller since 1971. For special applications the CRP (contra-rotating naval vessel. Three waterjet' families' are systems for improved motion control. The world's most advanced marine gas turbine, engine range for powers of 3.8MW - 15MW. product ranges. bridge automation, monitoring, control and From our Kamewa Ulstein range over 1,200 units propeller) unit offers high efficiency (10-15% available for a variety of applications broad product range suits all ship sizes with the WR-21 will power the Royal Navy's Type 45 dynamic positioning capability. Over 550 have been delivered to more than 40 navies and improvement) with low noise and vibration and manufactured in aluminum and stainless steel. naval and commercial versions. destroyer. The MT30 has been selected to systems are in naval service. coastguards. Kamewa fixed pitch adjustable the new Azipull pulling propeller is ideal for Rolls-Royce is also developing and testing the power the engineering development model for bolted propellers have been selected for the higher speed vessels. underwater discharge AWJ-21TM for future naval the US navy's DD(X) future surface combatant Royal Navy's Type 45 destroyer and our propulsor vessels requiring reduced signatures and and has been nominated to power the UK's design was chosen for the new Astute class improved manoeuvrability. Future carrier. submarine. Bergen B32:40 (2.9MW - 6.0MW) Bergen K series (0.9MW - 4MW) Bergen C25:33L (1.1MW - 2.7MW) Mooring winches and towing winches Bergen B (2.6MW - 5.3MW) Anchor windlasses and capstans Modular non-retractable fin area 0.85m² - 16.5m² Design and systems integration AG9140 (3MW) Crossley Pielstick PA6 STC (4.2MW - 5.7MW) Towed array sonar winches Gemini non-retractable fin area 1.4m² - 3.2m² Controllable pitch propellers 500kW-75MW HV/LV electrical distribution and Spey (19.5MW) Crossley Pielstick PA6B STC (5.3MW - 8.9MW) Deep-sea scientific winches power management Aquarius folding fin area 1.82m² - 7.48m² Actuator Type: Torque 3.7 - 45.7TM Fixed pitch propellers 4-8m diameter FF series: 40kW - 1,500kW WR-21 (25MW) Crossley Pielstick PC2.6 (6.6MW - 9.9MW) Electric, frequency controlled anchoring and Platform and vessel management Neptune folding fin area 3.8m² - 22.5m² Rotary Vane: Torque 2 - 256TM Adjustable bolted propellers A series: 500kW - 2,900kW MT30 (36MW) Crossley Pielstick PC2.6B (9MW - 15MW) mooring systems VTAS Automation and Control Passive tank stabilizer and rudder roll systems Ram Type: Torque 50.

Moving your business in the right direction propulsion The force in marine propulsion Rolls-Royce is the leading developer and supplier of propulsion equipment. A supplier who has the capability to meet your demands regarding performance and cost-effectiveness. Ongoing research and development is the key to the success of Rolls-Royce, with a total invest- ment in the overall product range exceeding £5 billion in the last decade. Combined with a technology and skills base accumulated over 100 years, Rolls-Royce today has the broadest range of propulsion products, services and expertise in the world. The Rolls-Royce commitment to customer State-of-the-art technology combined with the latest hydrodynamic design codes are routinely used in the optimisation of propulsion satisfaction is your guarantee of the highest equipment. levels of quality, expertise and performance. And with a truly international presence Rolls-Royce provides service and maintenance worldwide. World famous propulsion product names by Content: Rolls-Royce: Propellers/reduction gears page 2 - 9 Azimuthing thrusters page 10 -16 Kamewa™ Tunnel thrusters page 17 Kamewa Ulstein™ Ulstein Aquamaster™ Electrical Pod page 18 - 19 Bird-Johnson™ * Waterjets page 20 - 22 Customer support page 23 - 25 *Fixed pitch and controllable pitch propellers in the Bird-Johnson range are designed and manufactured to US Navy MIL standards. New Generation Workwheels® are supplied for the workboat market. Specialist literature available. 2 At the leading edge of propulsion technology reduction gears Propellers/ Unlike other propulsor suppliers, various propeller/ship afterbody tests. In the quest for optimum propulsion Rolls-Royce has its own marine One of the few free-surface type efficiency with minimum noise and propulsion laboratory in Kristine- tunnels in existence, the second tunnel vibration, Rolls-Royce engineers hamn, Sweden, equipped with two is used for testing high speed employ advanced theories and cavitation tunnels. A conventional propellers operating in partially or calculation methods. Since the closed recirculating cavitation tunnel fully submerged conditions, in parallel laboratory first opened in 1942, about is used for testing propellers in "open or oblique flow. Transverse and 1.200 models of sub-, semi-, and water" (i.e. not influenced by the hull) vertical forces can be measured in supercavitating propellers have been and behind the hull condition. This addition to thrust and torque, using a tested. tunnel offers maximum flexibility for six-component dynamometer. High skew Conventional Wake field behind after-body All propulsion products are delivered with By skewing the blades, noise and vibrations can be reduced to a minimum. remote control systems. The electronic control systems are undergoing continuous improvements to meet all technical and ergonomical demands. 3 Kamewa Ulstein™ controllable pitch propellers, XF5 D reduction gears Propellers/ OD box in front of gearbox Illustration showing type F system with oil distribution box mounted on the forward end of the reduction gearbox. The OD box incorporates the pitch feedback system. OD-box in shaft line Illustration showing type M mum overall installation space, and is system with oil distribution box therefore the most favourable in the shaft line. solution. Type M: A separate shaft carries the Typical oil distribution box, and additional applications: Suitable for intermediate shafts can be arranged larger vessels such as: between the propeller shaft and the • fast ferries OD box shaft. • cruise ships • container ships • cargo vessels The XF5 D is available in NiAl-bronze • tankers or stainless steel and is optimised for • naval vessels all types of installation, from no ice to • offshore vessels highest ice class, throughout the The XF5 D system is recognised as the moderate skew type, conventional or speed range. most efficient of its type on the market nozzle design. today. The hub/propeller ratio has Underwater replacement of blades as There are two types of Kamewa well as feathering design are optional been optimised for maximum Ulstein CPP systems – type F and features. efficiency and the blade bearing type M. arrangement modified to avoid peak The propeller is delivered with a low pressures.

Designing a new level of performance design and ship technology Setting standards for future ship design A well-designed ship is a result of collaboration, experience, innovation and state-of-the-art equipment. Founded on core values of reliability, integrity and innovation, Rolls-Royce designs ships as well as major systems on board.This unique concept of integration assures you performance second to none. Rolls-Royce offers a range of ship designs comprising offshore service vessels, coastguard vessels, fishing vessels and a wide range of merchant vessels.The UT-Design for offshore operations, launched in the mid 1970s, has The UT-Design and NVC- Design are tested in model tanks to become the world-leading design range for maximize speed and sea-keeping according to the offshore service vessels. Furthermore, the clients’ requirements. NVC-Design has been acclaimed in the fishing and merchant shipping sectors, maximising owners and operators continuous profitability. These solutions create added value thanks to optimal integration of vessel design and equipment, as well as effective supply chain management. Our products strike a harmonious Contents: balance between performance and ownership costs – all backed by a truly international Design principles pages 2- 7 customer support network assuring lifetime Offshore vessels pages 8-17 support and low life-cycle costs. Merchant vessels pages 18-25 World famous ship design names Fishing vessels pages 26-33 by Rolls-Royce: Global service & support pages 34-35 UT-Design NVC-Design 2 1 Experience and advanced technology Design principles UT-Design and NVC-Design vessels conditions. These analyses and test are in operation all over the world – results include all components vital to under the toughest conditions known the hydrodynamic characteristics of a to man. Working closely with vessel, such as the rudders, propulsion operators and crew members on these and stabilisation systems. vessels has yielded invaluable feed- back. These experiences form a vital Rolls-Royce is also a major supplier of base of knowledge which enables our ship equipment. Our approach to designers to develop optimal vessels. integration enables delivery of complete system solutions – from Hydrodynamics is at the very heart of concept and feasibility studies to ship Rolls-Royce's ship design. design, equipment selection, Understanding and solving procurement, systems engineering hydrodynamic challenges constitute and integration. key technology areas for future Offshore, passenger, cargo and fishing innovations within ship design. We vessels, either standard or customized, Rolls-Royce focuses strongly on developing use advanced calculation programs are all key features within our product safe deck operations. New safety solutions in ship design and automation of ship and tank tests to estimate and verify portfolio. equipment reduces the risk for dangerous ship motion in different sea situations. 3 Designs for better overall economy Our primary objective is to create a vessel in perfect harmony with the elements in which it will operate. To achieve this, we keep a strong focus on the overall economy, reliability, safety, and environmentally-sound designs. Each of these factors is vital to deve- loping profitable ship design. Our pool of in-house expertise in all design disciplines, and a vast range of ship equipment, makes us exceptionally skilled in balancing all these crucial factors to create holistic cohesion. Despite the complex combinations of optimal hull form, minimum ship worthiness, innovative arrangements But, first and foremost, decades of motion, safe operation, tailored ship and cost efficiency. For instance, the experience has taught us to avoid equipment and system solutions, first ever UT-Design vessel built in the compromising requirements specified Rolls-Royce designs simple and highly mid 1970s is still operating safely and by the ship owners, ship yard, functional solutions. A proven major at a profit for its owners. In addition to operator and crew. Our success is not benefit for shipyards and operators. this, our naval architects were worth much unless all parties involved in the construction of most of involved are comfortable with the UT-Design and NVC-Design have the North Sea fleet of offshore vessels. result. For us, the best reference is that won wide acclaim for their sea customers keep coming back. Rolls-Royce designs simple solutions for complex offshore, merchant and fishing vessels with high functionality – a well-proven major benefit for ship yards and marine operators. 4 The design process Design principles Basic design Detailed design Production details General arrangement Hull form design STRUCTURE STRUCTURE STRUCTURE Structural design Detailed hull design Production information Visualizations/ Tank plan & capacity Main structural analysis - Parts - Shrinkage & excess Presentations Main scantling drawings - Brackets - Welding & bevels Intact and damage stability Deck layouts - End cuts, etc. - Etc. Vessel specification Vessel performance MACHINERY Outfitting Nesting Cost/Benefit assessments - Motions & operability System drawings (P&IDs) - Deck arrangements - Position keeping Related calculations - Foundations N/C information - Manoeuvring Machinery layouts - Ladders, etc. Templates - Resistance/propulsion Panel line information - Vessel operation ELECTRICAL Accommodation Part lists simulation System diagrams - Insulation Cutting sketches Related calculations - Panels layouts of control room, - Ceiling, etc. MACHINERY wheelhouse etc. Isometric drawings MACHINERY Cutting information - Equipment arrangement Bending information - Piping arrangements Spool information Material lists ELECTRICAL - Equipment arrangement ELECTRICAL - Cable arrangements Material lists Quotation documentation > Performance documentation > Main class drawings > Workshop drawings > Production information Rolls-Royce is able to provide a well- costs for customers in all project designed by Rolls-Royce means that founded structure for ship design. We phases.