Engineering Excellence

for your Business

22ND February 2018, Athens Greece

 Steps of the Study

er
1 Week ak
M
TS
W
B 2-3 Weeks
of
n
c tio
e le
r S
Fo

Initiation of
the project Maker of BWTS has
been selected
 Feasibility Study
Duration 2-3 Weeks

1 Week

Maker 1 Maker 2

One final selected Maker or Short list of two Makers

 Retrofit Time Framework

Total abt. 12-16 Weeks

1 Week 3-4 Weeks 3 Weeks 8 Weeks

Phase 1: Basic Engineering Phase 2: Verification of Installation Area Phase 3: Detailed Engineering Phase 4: Approval Package &
Retrofit Specification*

Preparation of Preparation of Class

WBTP Area Match On-Board Inspection Final Wiring Drawings required Drawings

Preparation of Class Approval

3D Laser Scanning
Preliminary PID Preparation of Final Pressure Follow Up
Final PID Losses Calculation

Preparation of
On-board inspection
Preliminary Pressure
Losses Calculations
Isometric Drawings
Post Processing Point Cloud 3D Modelling of Selected
Areas - Equipment Cable Spec
3D Virtual Installation
of WBTP MTO
Preparation of 3D piping
Diagram – Isometric Drawings Supports Drawings

* Depends on required time by Classification Society for approval procedure

 The Study

RETROFIT STUDY

CONSULTING COMPANY MAKER TECHNICAL DEPARTMENT OF OWNERS SHIPYARD

Turn Key Solution

May Absorb the Cost of the Engineering Study
Appoint the study to a Consultant

LIABILITY

CONS. COMPANY 1 CONS. COMPANY 2 CONS. COMPANY 3 Maker??

Engineering Company??
Shipyard??
 Phase 1 – Basic Engineering
1x Ballast Pumps Capacity (One Common Syst.)
Required Data By the COMPANY 1 Model of WBTP will be selected 2x Ballast Pump Capacity (One Common Syst.)
1x BWTP for each Pump

• 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

Arrangement and Piping Drawings from 82k DWT Bulk Carrier

 Phase 1 – Basic Engineering

2 Possible Area of Installation of WBTP will be marked 3 Preliminary PID of Ballast/Bilge

Arrangement Drawings will be updated in line with WBTP Equipment layout(s)

2x1000m3/h WBP

Filter

TRO-N Unit
Filter

TRO Sampling Unit

4 Preliminary Pressure Losses Calculation for Ballast System

• Ballast Pipe Pressure Losses

• Ballasting and De-ballasting
Rates
C2E Units
C2E Units
3D Laser Scanning – Verification of Installation Area

• 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

3D Laser Scanning Technique to Point Cloud

Sample Engine Room Scanning Positions

 3D Laser Scanning – Verification of Installation Area

Registration

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.

Consider 360o Covering Consider 360o Covering

Scan no.1 on E/R Lower Floor Scan No.2 on E/R Lower Floor
 3D Laser Scanning – Verification of Installation Area

A Complete Registered Point Cloud Database – Grey Scale

• 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

82K DWT Bulk Carrier Engine Room and Steering Gear Room (Point Cloud)
 3D Laser Scanning – Verification of Installation Area

B Complete Registered Point Cloud Database – Colored

• 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)

 3D Laser Scanning – Verification of Installation Area

3D Laser Scanner by and EX-plosion Environment

Option 1
Focus3D
Use of Explosion Proof Laser Scanner for explosion
environment such as pump room, Upper Deck where part of
WBTP equipment may be installed

Option 2
Imager 5006EX
Use of conventional Laser Scanner

Scanning should perform during dry docking after all

necessary precautions has been made:

Specification a. Piping Gas free

b. Space gas measurements
c. Modification of Gas sampling device
• Small and compact design (dimensions 24x20x10cm - weight d. Portable measurements devices during scanning
5.0kg) 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/sec
with accuracy better than ± 2mm.
3D Laser Scanning – Verification of Installation Area

EX-plosion Environment

Focus3D Problems
Imager 5006EX
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

3D Laser Scanning – Verification of Installation Area

Common questions for the scanning are:

1 2 3 4

Accuracy Preparation Deliverables Cost

 3D Laser Scanning – Verification of Installation Area

Accuracy (of What????)

Accuracy of the registration

Accuracy of the scanning 2/3mm from scan position to scan position
1 2/3mm @ 100m Depends on the
2
Actually less than 1mm inside E/R or Pump Room post processing software
the operator of the scanner during scanning
post processing engineer expertise

Hint: Always request together the point cloud deliverable and the
report of the post processing software at the end of the
Accuracy of the measurement
3 registration. Whatever is less than 2/3mm in 3-axis and more than
Depends on the registration and on the operator of the viewer
0.1o-0.5o angle is unacceptable
 3D Laser Scanning – Verification of Installation Area

Preparation / Precaution (as applicable)

Preparations Precautions
1 1. Area(s) to be clean and tidy 2 1. No crew to be present in the off limit area(s) during scanning
2. No loose equipment to be in way of area(s) to be scanned 2. Instructions by the scanner operators and sup. Engineer(s) or
3. No work or repairs or survey to be performed in the area(s) to be officer in charge shall be strictly followed
scanned 3. Off limit areas(s) will be marked accordingly, markings to be
4. Engine room and pump room floor covers/grating to be removed respected, not violated and not removed
by the crew, according to the scanner operator’s instructions 4. Direct eye contact to the scanner lens to be avoided due to danger
5. Pump room ventilation to be in operation at max power during 3D of the eye sight
scanning 5. Contact/removal/change of location of the reference spheres or
6. Personal gas meter to be provided to scanner operators (two for checkered tables is strictly prohibited
operators and one for the scanner) 6. Works inducing vibrations in the vicinity of the scanner location
7. Gas meter to be installed in several locations in pump room and not to be performed
upper/s deck during 3d scanning 7. Scanner and its supports not to be touched by any unauthorized
8. Cargo lines inside pump room to be stripped personnel
9. Pump room bilges to be clean 8. Sup. Engineer(s) or Officer in charge to order immediate stop of
10. Gas sampling unit to be in operation. System interval to be set to the 3D scanning in case of gas sampling unit alarm (high gas
minimum rate. concentration)
 3D Laser Scanning – Verification of Installation Area

Deliverable(s)

Database and File Type

Which area(s) will be scanned?????
Complete registered database of all the scanned areas
1 Dedicated areas identified for the retrofit
2 Or multiple database for each scanned area without
Or all the engine room
connection between scanned areas (i.e. ER and Pump
Or/and pump room
room)
Or in addition the engine casing
Or in addition engine casing/funnel external
Raw data, FLS, Recap,E57, xyz, other
Or in addition cargo area/tanks (Framo type Tankers)

Something more than scan??

3
Assessment on the available space for installation Hint: Point cloud will be Owner’s/Operator’s property or property
New Pipes routing of the Company who performed the scan ?
Identification of the connection to existing piping
Identification of the spare MCCB for electric connection
 3D Laser Scanning – Verification of Installation Area

COST (for non Ex proof??)

Define what you pay for

For 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

400-1000$ / (day and operator)

1000$ block 6500$-8000$

fee per vessel block fee per
vessel
 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

 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
Routing Scenarios of the Main Pipes
 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
Maintenance Space Consideration
 3D Laser Scanning – Feasibility of BWTS Installation

New Operation profile for the ballast pump

Always request Pressure Loss Calculations and clear indication of the ballast flow
for the worst case scenario of ballast reduction resulting in increasing of ballasting
operation. time. This may define the final routing of the
pipes.
Phase 3 – Detailed Engineering

1 2 3 4

Class
Drawings Calculations 3D Modeling

Revision
 Phase 3 – Detailed Engineering
1 Class Drawing Revision
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
1
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
 Phase 3 – Detailed Engineering

2 Calculations 1

Tricky Part
Final Calculations
• Short Circuit calculations
• Final Calculation of Pressure losses and new flow rates of Ballast (not available drawing to the class, not complete defined variables during the
Piping System calculations, needs software for the calculation with certification of IEC61363

• Final Calculation of Pressure losses and new flow rates of Cooling or • Actual Operation profile of D/Gs
Heating System
• Calculation of MSB Bus Bar and Branches if required
• Final Calculation of Power Consumption
• Amendment of Electric Power Balance • Actual needs of vessel operation

• New Electric Operation Profile to be defined • Flow rate of auxiliary equipment (i.e. cooler, heater)
• New Ballasting/De-Ballasting rates/time to be defined
• Equipment Supports Structural Strength calculations (*if required)
 Phase 3 – Detailed Engineering

2 Calculations 1

Short Circuit Calculation Pressure Drop Calculation

 Phase 3 – Detailed Engineering
Tricky Part
3 3D Modeling 1 • 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)
 Phase 3 – Detailed Engineering
Tricky Part
3 3D Modeling 1 • 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)
 Phase 3 – Detailed Engineering

3 Technical Specification and drawings 1

 Phase 3 – Detailed Engineering

3 Technical Specification and drawings 1

 Phase 3 – Detailed Engineering

3 Technical Specification and drawings 1

Assembly Drawing Connection(s) Drawing

 Phase 3 – Detailed Engineering Tricky Part

• Spool Pieces
3 Technical Specification and drawings 1 • Final adjustment on board (field weld for flanges, extra length)
• Pipe fitting compatible with selected shipyard and Maker

Isometric Drawing with MTO Fabrication Drawing

 Phase 3 – Detailed Engineering

3 Technical Specification and drawings 1

Pipe Proposed Support

 Phase 3 – Detailed Engineering

3 Material Lists 1
Cabling MTO
Steel Beam MTO

Pipe MTO
 Phase 3 – Detailed Engineering

3 Material Lists 1

Steel Beam MTO

 Phase 3 – Detailed Engineering

3 Material Lists 1
Pipe MTO
 Phase 3 – Detailed Engineering

3 Material Lists 1
Cabling MTO
 Retrofits of SOx Scrubbers Source: Clarkson

222 Ships (July 17)

Maker 11 Maker 1
1 Week Maker 10 8% 3%
15% Maker 2
23%

Maker 9
6%
Maker 3
9%

Maker 8
10% Maker 4
5%
Maker 6 Maker 5
Maker 7 3%
4%
3%
 New Orders with SOx Scrubber Source: Clarkson

75 SHIPS (JULY 17)

Maker 9 Maker 1
9% 10%
1 Week Maker 2
Maker 8 3%
11%
Maker 3
3%
Maker 7 Maker 4
11% 1%

Maker 6
3%

Maker 5
49%
 Prediction for Global Marine Use

Source: BP
Source: Shell
1 Week
 Requirements to be integrated

Shipping M/E, G/E & Boilers’

Scrubber Vendor Class Other Engineering
Company Makers

1 Week

Vendor’s Makers Ø Arrangement &

Ø Sets the time Class Rules and
requirements and requirements & installation details in
duration for the Guidelines
guidelines guidelines line with good
retrofitting marine practices
Ø Requires Ø Redundancy
minimum time Ø Operation Flexibility
in the repair Ø Maintenance issues
Shipyard Ø Minimize repair
Ø Minimize Costs work
and operation Ø Calculations/design
headaches not being Class
items
Demanding Multi
Task Design
 Steps of the Study

1 Week
 Keep in mind

Offered Technical Specification

1Ø Shipping
Week 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 assessed
Ø 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.
 Keep in mind

Arrangement Aspects

1 Week ØFunnel/Casing modification

ØBends of large diameter exhaust gas piping
ØMaintenance (e.g. exhaust gas piping bellows)
ØSW washing overboard discharge(s) location
ØRadars Blind Zones
ØFunnel Mark
ØVibrations
ØAccess
ØE/R Ventilation ducts
ØECR & ECC arrangement
Ø Funnel/Casing aesthetics
 Keep in mind

Calculations

1Ø Exhaust
Week gas piping back pressure Calculations. The challenge is on the modelling of exhaust gas
mixing.
Ø Exhaust Gas Piping Thermal Deflection Calculations
Ø Exhaust Gas Piping stress calculations iwo tricky arrangements
Ø Tower’s Foundation and Bracing strength calculations. Dynamic loads should be considered
Ø Short Circuit Calculations
Ø Assessment of the S/C and Main Sea Cross Line size
Ø CFD Analysis of the SW washing overboard discharge
Ø Assessment of the installed Fixed Fire Fighting Capacity
Ø Electric Load Analysis
Ø Stability assessment
Ø Equipment Number assessment
 Keep in mind

Class Aspects

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

On Board Testing

1 Week
Ø Makers, Class, Shipyard & Shipping company are involved. Tests’
Scheme should be prepared and mutually agreed well in advance
Ø M/E, G/Es & Boilers’ transient operation profiles should be checked
Ø Tests with the vessel chartered may be required.
Ø HFO with 3.5% sulphur should be available
Ø Exhaust gas back pressure measurements should be carried out in line
with M/E Makers Guidelines
Ø SW water temperature and alkalinity to be close to the design values
 Keep in mind

Technical
Department should
About 6 Affects the be pro-active. At
Top months for Limited Time operation of least detailed
Demanding
Management Innovative Several Parties having a for the M/E, G/Es and feasibility study
Engineering
Decision Involved concluded installation Boiler(s) should be carried
design operation out and conclusion
on a Maker, if
practicable