Retrofit of ballast water treatment plants

Transcription

1 Germany Retrofit of ballast water treatment plants Gerd Hagemeister (GM) Foil 1

2 3D Design in Shipbuilding 45 years of experience Lübeck - Germany 660 TEU 280 t Bollard Pull TUG 3D ER Design 3D ER Design MEKO A 200 S.A.N. 3D ER Design Foil 2

3 References in shipbuilding (excerpt) Customer Howaldtswerke Deutsche Werft AG (HDW) Cassens Shipyard Flender Shipyard Shipowner Buss Blohm+Voss Blohm+Voss Flender Shipyard Münchmeyer Petersen Marine (MPC) Münchmeyer Petersen Marine (MPC) Shipowner Buss Shipowner NSC Hitzler-Werft / Ferrostaal Blohm+Voss Blohm+Voss Hitzler-Werft / Ferrostaal Hitzler-Werft / Ferrostaal Shiptype Shipyard Superfast-Ferries 6 10 HDW / Kiel Multi Purpose Cargo Vessel 4350 tdw Zhoushan Shipyard / China Superfast-Ferries Flender Shipyard / Lübeck Container Cargo Vessel 660 TEU Zhoushan Shipyard / China Frigates South Africa Blohm+Voss / Hamburg Corvettes Malaysia Blohm+Voss / Hamburg / Malaysia Container Cargo Vessel 3600 TEU Flender Shipyard / Lübeck Ro-Ro Vessel 6000 tdw Alexandria Shipyard / Egypt Container Cargo Vessel 2500 TEU ISOICO Shipyard / Iran Container Cargo Vessel 900 TEU Zhoushan Shipyard / China Container Cargo Vessel 1200 TEU YES Jiang Eastern Shipyard / China 200t Bollard Pull Tug Mützelfeldt - Werft / Cuxhaven Mega-Yacht SAFARI Blohm+Voss / Hamburg Mega-Yacht ECLIPSE Blohm+Voss / Hamburg 220t Bollard Pull Tug Mützelfeldt - Werft / Cuxhaven 280t Bollard Pull Tug Mützelfeldt - Werft / Cuxhaven Foil 3

4 References in shipbuilding (excerpt) Customer Nobiskrug / Abu Dhabi MAR Hitzler-Werft / Ferrostaal Nobiskrug / Abu Dhabi MAR Hitzler-Werft / Ferrostaal Aquijo Ltd. Ananda Shipyard & Slipways Ltd. Nobiskrug / Abu Dhabi MAR Blohm & Voss Naval Shiptype Mega Yacht (NB 781) 100t Bollard Pull Tug Mega Yacht (NB 782 / 783) Platform Supply Vessel Sailing Yacht NOVA Multi Purpose Cargo Vessel 6100 tdw Mega Yacht (NB 423) Fregatte F 125 Shipyard Nobiskrug / Rendsburg Mützelfeldt - Werft / Cuxhaven Nobiskrug / Rendsburg Bharati Shipyard / India Factoria Naval Marin / Spain Ananda / Bangladesh Nobiskrug / Flensburg Blohm & Voss Shipyards Foil 4

5 Foil 5 Schedule of Retrofit Diagram ER-Plan 3D-design Pipedrawings (Isometrics) As-Builtdocum. Parts-lists S e a ch es t S e a ch es t H e at H e at Ch em / Biol. Ch em / Biol. C hl or in ati o n C hl or in ati o n O zo n ati o n O zo n ati o n Fil te r Fil te ru V U V B all as t ta nk B all as t ta nk C av ita tio n C av ita tio n Ul tr as o u n d Ul tr as o u n d D e ox yg e n. D e ox yg e n. U V U V El ec tr ol ys is El ec tr ol ys is Fil te r Fil te r H yd ro cy cl o n e H yd ro cy cl o n e C o a g ul ati o n C o a g ul ati o n Technique and Supply Ballast Water Treatment General notes

6 Ballastwater - necessary for balance of unloaded ship - transport medium for little organisms being carried around the world Example of distribution of ballast tanks on a double-hull vessel Foil 6

7 Why Ballast-Water-Treatment? Ballast-Water spreads invasive organisms such as creatures, baceria and viruses all over the world. Ecosystems become disrupted, flora and fauna become influenced or suppressed. Invasive organisms can even threaten our health by causing serious epidemics Foil 7 Preservation of the environment and human health and prevention from damages at coastal regions. IMO Guideline 9, D2

8 IMO 2004: Status today Ratifikation and entry into force 30 flag states must have signed which represents 35 % of the world wide tonnage ( gt ) 36 sates have signed which represents 29,07 % of the world tonnage, Germany and some other smaller flag states are close to the signing process but this will come up to only appr. 31 % of the tonnage The US Coast Guard didn t want to wait any more, they set the IMO 2004 into force at the end of May 2012 For most of the other countries, the ratification is still pending Open issues are: - How many suppliers with which amount of capacity are available? - 30 to 40? - How many of them got the us coast guard acceptance? - Only 1? - More? -What s about sampling, quick sampling? Still in development! Foil 8

9 IMO 2004: Status today US Cost Guard legislation - June 2012: new legislation enter into force - USCG discharge standard = IMO standard - Application for the Type Approval by USCG not possible to date (approx. 2013) Alternate Management System AMS is intended as an interim measure to allow foreign type- approved BWMS to be used on a vessel for up to 5-years, which will allow the BWMS vendor sufficent time to obtain U.S. type approval, 6 systems gained AMS status. Vessels Category Ballast Water Capacity Date of Construction Vessels Compliance Date New Vessels All 01.Dec 2013 or newer On delivery Existing Vessels < 1,500 m³ Before 01 Dec 2013 First scheduld drydocking after 01 January ,500 5,000 m³ Before 01 Dec 2013 First scheduld drydocking after 01 January 2014 > 5,000 m³ Before 01 Dec 2013 First scheduld drydocking after 01 January 2016 Foil 9

10 Options for ballast water treatment Mechanical solid-liquid seperation Filtration : disc-, screen filters (generally with automatic backflushing into the ocean) Physical treatment UV : Ultraviolet Light (altering and destruction of DNA; influencing and reducing the reproduction of species; limited by water turbidity, mostly higher energy consumption) Chemical /active treatment Chemical Biozids : Disinfectants (toxication or oxidation of cell membranes with e.g. peroxo-carbon-acids of hydrogen peroxide; needs to be neutralized) Hydrocyclone : (based on centrifugal forces; limited by specific density of species versus water) Cavitation US : Ultrasound (destruction of cell membranes) Electrochlorination: generating free chlorine, sodium hypochlorite and hydroxyle radicals (penetration and destruction of cell membranes) Electromechanical Separation Coagulation / Flocculation Desoxygenation (substitution of N 2 ; add. corrosion protection; exact concentration need for several days) Ozonation Generating of Ozone O 3 as strong oxidative substance (penetration and destruction of cell membranes) Membrane filtration Thermal treatment e.g. from exhaust gas Active substances or organisms like viruses Foil 10

11 Collection of BW-treatment options offered by the suppliers Heat Chem / Biol. Chlorination Filter UV Ozonation Sea chest Filter Cavitation Ballasttank Electrolysis Ultrasound Hydrocyclone Deoxygen UV Coagulation Foil 11

12 30 to 40 BWT-Systems available Creteria for Choice of BWT- Systems - technique(s) - efficiency - space requirements - maintenance - costs (investment / service) Foil 12

13 Schedule of Retrofit New Building Retrofit Involved in the Design process System directly integrated into design - Recommended space - Connection to Ballast pipes - Connection to support systems and addional ingrediants - sufficient Energy supply On top of an existing Design - no space, no connections, no supply - already changes to the original design and equipment - out-dated, incomplete and/or missing documents and data - Usually available only 2D-Data Foil 13

14 Quality 2D-Data for Retrofit Available Drawings Conversion / Import Updated and modified Drawings for Retrofit and Classification DWG, DXF Direct modification top-quality PDF (directly from DWG, high resolution & contrast) Modification after Conversion and Import low-grade PDF / Scan / Image-File REDRAWING Completely or in extracts Effort /Costs Foil 14

15 Step 1: Check Ballast Water Diagram Example 1: TEU MPV Foil 15

16 Step 2: Redraw and Proposal Example 1: TEU MPV Foil 16

17 Step 3: Check Engine Room Arrangement Plan (ER-Plan) ER-Plan shows: - Main equipment - Tanks - Dimensions Missing: - Steel - Piping - Cables - Other equipment - insulation... Example 2: tdw MPV Foil 17

18 Step 4: from 2D to 3D 2D-Drawing IMPORT 3D Example 2: tdw MPV Foil 18 3D to get first impression of dimensions and space

19 Step 5: As-Built Documentation 5.1 Manual Measuring Example 2: tdw MPV 3D-CAD assembled from manually taken data Foil 19

20 Step 5: As-Built Documentation 5.2: 3D - Laserscan Scans from 5 to 12 different angles and positions Scan results merged to one Point Cloud Example 3: Gas tanker 3D-CAD assembled from Point Cloud Foil 20

21 Step 6: 3D - Design 6.1: 3D - CAD BWTS: Crystal Ballast Filter + UV 500 m³/h Concept for arrangement to fit into the measured available space Foil 21

22 Step 6: 3D - Design 6.1: 3D - CAD Foil 22

23 more examples Foil 23

26 Step 6: 3D - Design 6.1: 3D - CAD To be taken into account (1/2): Limiting factors to Retrofit - Classification of the ship (e.g. Germanischer Lloyd, Lloyd's Register, ClassNK,...) - Type of vessel and according regulations (Gas tanker: additional security issues) - Norms of the specific systems (e.g. Ballast water system, fuel supply system, ) - Standards (DIN, DIN EN ISO, JIS, ) differ in dimensions of joints, pipes, - small ships have less space in engine rooms - operating areas have to remain free (e.g. Gangway min. 600 mm x 2000 mm) - room height has to be considered - entrance to existing equipment for operation and maintenance, - stairways, emergency exits, man holes has to be kept free - pipe crossings ( cross over ) below floor in most of the cases not possible Foil 26

27 Step 6: 3D - Design 6.1: 3D - CAD Limiting factors to Retrofit To be taken into account (2/2): - operating space for screws, bolts, nuts, handles, - no connections of fluid pipes above electrical devices - additional space for insulation - systems to be avoided (e.g. Thermal Oil-Pipes) - no welding close to / on tanks because of tank coating - minimum distance between pipes / components - usage of standard parts for repair - standard pipe elbows with bending radius of 1xdiameter or 1,5xdiameter (1D, 1.5D) - angles of pipes always multiple of 15 - minimum distances between pipe bends due to fabrication...etc. Foil 27

28 Step 6: 3D Design 6.2: Calculations Additional Energy requirements due to new equipment and pipework Foil 28

29 Step 7: 2D - Drawings 7.1: Isometrics Foil 29

30 Step 7: 2D - Drawings 7.2: Foundations and detailed assembling drawings Foil 30

31 Step 8: Ordering details Parts lists Foil 31

32 And finally the Retrofit can start... during voyage or maintenance Foil 32

33 Thank you very much for your attention Gerd Hagemeister Foil 33