C O N S U L T I N G & E N G I N E E R I N GHow to Choose and Integrate BestSystem that Fulfills Your RequirementsHenrik BachérVP Consulting & EngineeringElomatic Oywww.elomatic.com4th Ballast Water Management Summit11-12.4 2011, Amsterdam, The NetherlandsC O N S U L T I N G & E N G I N E E R I N GObjectives of the presentationGeneral overview of BW treatmenttechnologies, system selection andinstallation considerationsFocus on retrofits;- the choise of system is more challenging in retrofits- many key considerations are applicable for NB’s just as well.- in NB’s however this is one system out of several to be designed andinstalled, the degrees of freedomare higher, shipyard responsibilityNeutral approach, no supplier preference nor technology rankingC O N S U L T I N G & E N G I N E E R I N GMarine MechanicaldesignProcessindustryCADMATIC3DsoftwareA multidisciplinaryconsultancy &engineering companyFinnish, privatelyownedAbt. 650 employees11 Offices in 5countriesC O N S U L T I N G & E N G I N E E R I N GMarineFrom conceptual development todetail design of all disciplinesFrom cruise vessels to working craftFrom newbuildings to conversions andretrofitsOur clients include shipowners,operators shipyards, equipmentsuppliers and many more in themaritime clusterC O N S U L T I N G & E N G I N E E R I N GContents1. General considerations and challenges2. BWT technology3. Vessel specific considerations andindicators4. The process of choosing solutions5. The role of design & engineering6. Installation aspects7. Conclusions1. General considerations and challenges2. BWT technology3. Vessel specific considerations andindicators4. The process of choosing solutions5. The role of design & engineering6. Installation aspects7. ConclusionsC O N S U L T I N G & E N G I N E E R I N GWhy do we need BW treatment? What is behind theconvention ?S.Saesmaa/ Finnish Environmental InstituteC O N S U L T I N G & E N G I N E E R I N GGeneral considerations and challengesEach ship is unique and should be dealt with as suchThis 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 andinterpreatations + regional/local requirements (US)•Technology, installation and operational challengesThis is no ”rocket” scienceC O N S U L T I N G & E N G I N E E R I N GGeneral considerations and challengesSpecial vessels; practical solutions fora.o. barges, semisubmersibles, dredgersetc. are neededIndustry tendency; leave the retrofit to the last minute tobe sure of what to doand a (false) expectation for a broadercompetition and thus lower pricesCritical issues;- equipment supply- engineering capacity-installation capacityAbt. 20 retrofits/day during the coming yearsShips to be convertedYear 2012 2013 2014 2015 2016 2017 2018 2019No of ships 1700 3000 3000 6000 6000 16000 14000 14000Tankers > 100.000 tdw existing abt. 1400NB's abt. 500Bulkers > 100.000 tdw existing abt. 750NB's abt. 700C O N S U L T I N G & E N G I N E E R I N GThe BWM Convention Regulation B-3Built BW m3 2005 2006 2007 2008 2009 2010 2011 2012 2013 2014 2015 2016< 2009 1500-5000< 2009 <1500>5000≥2009 <5000≥2009< 2012>5000≥2012 >5000D1/D2D2D1/D2D2D2D1/D2D2D2Source TraFiD-1 standard; BW exchangeD-2 standard; BW treatmentFirst intermediate or renewal survey after theanniversary date of deliveryof ship, whichever firstC O N S U L T I N G & E N G I N E E R I N GBW treatment technologyAbt. 50 manufacturers of BWtechnologies on the market11 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 approvalType approval by flag administration 12 systems at leastAdditional 3 applications for basic andfinal approval which could not be handledin MEPC 61 will be handled in MEPC 62(July 11 -15, 2011)and additionalapplications and approvals are expected during 2011MEPC 62 will focus on shipswith BW capacity > 5000 m3MEPC 62 will approve guidelines for othermethods as well as upscaling ofsystemsC O N S U L T I N G & E N G I N E E R I N GBW treatment technology- Mechanical filtration (28)- Hydrocyclone (3)- Chemical enchantment (coagulation/flocculation)- Mechanical filtration (28)- Hydrocyclone (3)-Chemical enchantment (coagulation/flocculation)DisinfectionPhysical pretreatment and solid/liquid separationResidual controlResidual controlC O N S U L T I N G & E N G I N E E R I N GBW treatment technologySource IMOG9C O N S U L T I N G & E N G I N E E R I N GSource IMOG9C O N S U L T I N G & E N G I N E E R I N GSource IMO+ RWO CleanBallast, Unitor BWTSC O N S U L T I N G & E N G I N E E R I N GBW treatment technologyCombinations of technologies are also adoptedSupplier focus on various capacity ranges (100 – 7000 m3/h, even >10.000m3/h)Serial or parallel installation to increase capacityModular solutions/distributed equipmentOperational modes- ballasting, ballasting & discharging,filter bypass on deballast, during voyage- neutralization of chemicals prior dischargeOperational costs- major factor for most systems; power(large consumers are eg. elctrolytic andadvanced oxidation processes)- chemical systems; chemicalsC O N S U L T I N G & E N G I N E E R I N GInstallations and experienceAbt. 350 systems sold/installedAbt. 200 vessels, mostly NB’sRetrofits limited, abt. 10 %of the sold/installed systemsRetrofits include ao. car carriers, bulkers, tankers, passenger vessels,container vessels, special craftSeveral systems (suppliers) have accumulated running hours and someexperience have been gainedC O N S U L T I N G & E N G I N E E R I N GWhich BWT solution for my ship ?The ideal objective: max benefit to lowest(overall) costEach ship is individualThere exists no standardized general “bestsolution”A thorough system comparison andconsequence analysis is the starting pointC O N S U L T I N G & E N G I N E E R I N GGeneral considerations in selecting BWT solutionsShip type & sizeTanker , bulker, container, carcarrier , passenger etc.Ship type & sizeTanker , bulker, container, carcarrier , passenger etc.Trading pattern, routesWorld wide traffic, short sea shipping,regular line service, operating areas(seas)Trading pattern, routesWorld wide traffic, short sea shipping,regular line service, operating areas(seas)Operational aspectsReliability, safety, servicerequirementsOperational aspectsReliability, safety, servicerequirementsEconomical aspectsInitial capex, operational costsEconomical aspectsInitial capex, operational costsTechnical aspectsPhysical, materialTechnical aspectsPhysical, materialPerformance, ballast needsCapacity and flow rate requirementsPerformance, ballast needsCapacity and flow rate requirementsCompliance!C O N S U L T I N G & E N G I N E E R I N GTechnical/operational considerations and key aspectsPerformance considerationsRequired time to be effectivePerformance considerationsRequired time to be effectiveCapacityBallast pumping and treatment ratesCapacityBallast pumping and treatment ratesMaintenanceCrew training and workloadAccessibilityMaintenanceCrew training and workloadAccessibilityPower requirementsAdditional need, existing capacityPower requirementsAdditional need, existing capacityTechnologyFootprint , weight, gas safeequipmentTechnologyFootprint , weight, gas safeequipmentExisting BW systemNo of systems, integrationExisting BW systemNo of systems, integrationInstallation aspectsAlterations in existing structuresComponent location flexibilityInstallation aspectsAlterations in existing structuresComponent location flexibilityCorrosionTanks, material selectionCorrosionTanks, material selectionC O N S U L T I N G & E N G I N E E R I N GTechnical issuesExamples of technical matters needed to be worked out in close cooperationbetween all parties- bypass options (emergencyif the BWT inoperable)- backflushing filters- vent lines from the BWT system (termination on deck or in the engineroom spaces dependingon 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 issuesC O N S U L T I N G & E N G I N E E R I N GTechnical issues cont.Special tanker considerations- fore and aft BW systems- pipes from BW tanks adjacent tocargo tanks not into the engine room- on deck installations currently under discussion (pump head requirementsincrease)- limitations of electrical componentsin the cargo pump room (except forexplosion free lights) pre/post 2007, zone 1 (IEC 60092 – 502)- possibility to re-class hazardousarea from pre to post 2007 standards- BW pump capacity, 10.000 m3/h or moreC O N S U L T I N G & E N G I N E E R I N GAutomation, control and monitoring-BWT system requirements-automation and control equipment for monitoring and adjusting treatmantdosages and/or intencities-a continuous self-monitoring functionduring the period in which the systemis in operation-recording of functioning and failure + data storage-alarms-audible and visual alarm signals inall stations from which BWoperations 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 activationC O N S U L T I N G & E N G I N E E R I N GAutomation, control and monitoring-control system location options-local panel-ECR-CCR-integration to existing automation and/or BW systems,-operation and control-alarmsC O N S U L T I N G & E N G I N E E R I N GThe solution evaluation processScore sheetSystemABC DOperation PrincipleFilter Filter Filter ElectroUV UV Cl lysisScore scale: 0-10,10 being the bestWeight factorPerformance and capacityPurificationFilter min. particle size (μm) 0,14 8 6 10Disinfection performance (technology) 0,3997 9Zoo plankton [per/ m3] (limit 10) 0,2686 6Photyplankton [per/ml] (limit 10) 0,2686 6Vibrio Cholerae [per/100ml] (limit 1) 0,16 10 6 6Escherichia coli [per/100ml] (limit 250) 0,16 10 6 6Intestinal Enterococci [per/100ml](limit 100)0,16 10 6 6Total7,3 9,7 6,9 7,9ProcessFlow rate per unit and maximum flow 0,5897 6Energy consumption (kw/m3) 0,610 5 7 8Chemical consumption (mg/l) 0,710 10 5 10Pressure loss [bar] 0,54 4 7 10Working pressure 0,1566 6Ex-class 0,3837 8Supply water (l/min) 0,1884 8Total22,7 18,8 17,8 23,6Total Technology Subscore30 28,5 24,7 31,5Score sheetSystemABC DOperation PrincipleFilter Filter Filter ElectroUV UV Cl lysisScore scale: 0-10,10 being the bestWeight factorDimensions and modularizationSize of the 250-334 m3/hu0,4724 7Footprint of 250-334 m3/h 0,6732 1Size for 2000m3/h unit [m30,4825 8Footprint of 2000 m3/h unit0,6637 7Modularization 0,8774 5Weight in operation [kg] 0,1856 6Total Size Subscore20,2 11,3 12,8 15,4Total Size Score8,5 5 6 7Equipment costEquipment cost [€] 0,8Installation costinstallation cost 0,5323 3Installation timeinstallation time 0,3322 2Operational costsoperational costs 0,8643 8ReliabilitySupport network 0,8868 4References 0,6423 8certificate/imo compliance 0,5533 5Total Reliability Subscore11,3 7,5 9,7 10,5Total Reliability Score9 7 7,5 8Lead timeLead timeTOTAL SCORE48 36 34 47,5C O N S U L T I N G & E N G I N E E R I N GThe solution evaluation processValue for moneyGood quality, expensiveHigh costLow cost, limitedperformanceC O N S U L T I N G & E N G I N E E R I N GThe retrofit processSolution & consequenceevaluation, comparisons,preliminary (basic) designSolution & consequenceevaluation, comparisons,preliminary (basic) designSupplier selectionSupplier selectionBasic design & eng.Basic design & eng.PlanningPlanningInstallationInstallationTesting &CommissioningTesting &CommissioningLogisticsLogisticsProcurementProcurementGeneral ,Technical,OperationalconsiderationsGeneral ,Technical,OperationalconsiderationsIndividual contractsTurn key (yard or supplier)EPCMIndividual contractsTurn key (yard or supplier)EPCMDetail designDetail designC O N S U L T I N G & E N G I N E E R I N GThe role of design & engineeringA ship specific optimum solution requires a deep cooperationbetween shipowner, BWT supplier and the design &engineering partyThe 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 androutes (component size, existing hatches, working openings)- classification & flag authority issues and approvals- general naval architecture issuesThe detail design can commence once all approvals are inplaceC O N S U L T I N G & E N G I N E E R I N GThe role of design & engineering cont.Only a thorough design can guarantee agood result; the more you design and planthe more you will control and influence(=reduce) costs and avoid surprises.3D design may be an advantageC O N S U L T I N G & E N G I N E E R I N GSupporting design tools – laser scanningWhat is laser scanning?Measuring method to get 3D data (accuracy 0,1 – 5 mm)Point cloud created by laser scannerPoint cloud edited to engineering format as a 3D modelWhy laser scanning?When documentation is poor or only old system drawingsare availableEnsures the present as built status with high accuracyCreates an ideal basis for the retrofit designEnables use of todays design toolsNeed for ship visits is reducedDesign errors are reducedNew components can be delivered as prefabricated unitsPotential to reduce total costsLaser scanning point cloud3D Basic modelRetrofit design modelC O N S U L T I N G & E N G I N E E R I N GSupporting tools – laser scanning cont.Example of a recent laser scanning raw data (contains also numerical information)C O N S U L T I N G & E N G I N E E R I N GInstallation considerationsOut of service - drydocking or alongside-Justified in combination with a scheduleddrydocking-When large working/transportationopenings are needed in the hull-When new hull overboard penetrations areneeded-Preparatory and finalization work can bedone while in service in order to minimizedown time-Advantages; infrastructure, logistics, labor& material in case of surprises-Disadvantages; loss of earnings (unlessstreamlined with a scheduled drydock)C O N S U L T I N G & E N G I N E E R I N GInstallation cont.In operation-Possible if a drydock is not needed; severalretrofits carried out prove that-Requires extensive planning-A high degree of prefabrication is needed-Logistics may be a challenge and needs strictmanagement (depending on trading pattern)-Solutions to enable theminimizing of hot work-Special solutions should be considered (pipecouplings etc.)-The design is in a key position-Disadvantage; poor coverage againstsurprises (material, special workforce etc.)C O N S U L T I N G & E N G I N E E R I N GAlternatives to ballast solutionsWhy ballast?Immersion (propeller, bow), trim(optimum running condition, avoidslamming), load distribution (strength), stability, anti-heelingBallast 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 WavesC O N S U L T I N G & E N G I N E E R I N GConclusionsThe BW convention is expected to enterinto force within a reasonable futureThere is no general best solution – each ship is individualThere is a number of proven technologies on the marketA thorough pre-design/evaluation study pays offRetrofit installations including logistics needs to be planned in detail with highpriorityDesign capacity, equipment supply and installation capacity may become criticalC O N S U L T I N G & E N G I N E E R I N GThank you for listeningQ & Ahenrik.bacher@elomatic.com