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PAGE 8 DIESELFACTS 1/2010 PrimeServ Retrofit Increases Propeller Efficiency by Impressive 12% Retrofit propeller solution delivers significant fuel savings to passenger ferry An optimised propeller from MAN Diesel has helped the Scandlines passenger ferry, the M/V “Sassnitz”, achieve increased efficiency of 12% on its daily sail between Trelleborg, Sweden and Sassnitz, Germany. Scandlines is one of Europe’s largest ferry companies, a result of the fusion between the largest, national ferry lines in Denmark and Germany. Business is based on the swift and reliable transport of both passengers and cargo on international routes within Danish, Fitting the new propeller blades German and Swedish waters, as well as further afield to the Baltic states and Finland. Scandlines operates 17 ferries on 8 routes between 11 harbours in the Baltic Sea. Last year, the shipping company transported more than 17.3 million passengers, 4 million cars, 1 million lorries, 84,000 goods wagons, and 68,000 busses. Rasmus Nielsen, Scandlines’ project engineer says: “We started to look at propeller retrofit solutions as a direct consequence of The M/V Sassnitz sails daily between Trelleborg, Sweden and Sassnitz, Germany high fuel prices. Aboard the M/V Sassnitz, we have replaced the propeller blades with a modern, optimised design. Our tests document that this has realised an increased efficiency of no less than 12%. Originally, MAN Diesel had 8-10% as a target, so therefore it’s very pleasing that our measurements show an even better result.” He adds: “The ship reverses a lot in-harbour and therefore it’s vital for us to attain the optimal propeller blade design. As such, the propeller set-up has been optimised to best fit this particular operating profile without compromising overall efficiency.” In order to optimise the process, the Sassnitz’s operating profile was thoroughly analysed by MAN Diesel’s propeller design department. MAN Diesel PrimeServ participated in the installation of the new propeller blades on the Sassnitz, which is powered by four MAN L40/54 engines. “MAN Diesel and Scandlines have cooperated with each other for over 20 years on controllable pitch propellers,” says Brian Grusgaard, Manager of Upgrading and Retrofit Support at MAN Diesel Propulsion After-Sales. “Scandlines is a front runner within retrofit propeller optimisation and the M/V Sassnitz’s fuel consumption has now been reduced, which is also an environmentally friendly solution. We expect many such retrofits in the future, and are currently in contact with a good number of other shipowners who are interested in propeller optimisation.” Rasmus Nielsen, Scandlines project engineer, and Brian Grusgaard, Manager of Upgrading and Retrofit Support at MAN Diesel Propulsion After-Sales M/V Sassnitz Principal Data Route Sassnitz – Trelleborg Type Ro-Pax Construction year 1989 / 1994 Gross tonnage 21,154 Shipbuilder Danyard A/S, Frederikshavn, DK Port of registry Sassnitz Flag German Engines 2 × MAN 8L40/54 Output (kW) 18,200 Length, oa 171.5 m Breadth incl. fender 24.1 m Service speed 19 kn 2 x MAN 6L40/54 Train capacity 5 tracks, 711.5 m
DIESELFACTS 1/2010 Hazardous Substance Declaration to Lead to Cleaner Products MAN Diesel initiative pre-empts IMO ship recycling regulations for newbuildings For reasons of cost, the final scrapping of ships and the recycling of materials have gravitated to developing countries and attract considerable criticism regarding the working conditions of the personnel involved and the disposal of potentially harmful residues in the ships. In particular, given lifespans of merchant ships in the region of 30 years, the scrapped hulls can contain substances which have long been identified as hazardous and outlawed in many parts of the works. Examples are asbestos and lead which were widely used as insulation for pipes and in paints respectively, before their risks were recognised. To counter this situation, the International Maritime Organisation has developed the IMO Convention on Safe and Environmentally Sound Recycling of Ships, a set of regulations controlling the use of hazardous substances in newbuildings. The legislation started ratification in 2009 and affects newbuildings with keels laid in about 2013. Sensibly, the legislation applies to all the components of the ship and places the onus on the manufacturer to minimise or, where possible, completely eliminate harmful substances from their products. Any unavoidable residual substances must be entered in an Inventory of Hazardous Materials (IHM) issued by the shipyard and based on the declarations from its suppliers. As an engine, turbocharger, gear and propeller supplier, MAN Diesel’s products are categorised as “Structure and Equipment” under the IMO Convention. MAN Diesel is obliged to issue declarations under Table A Materials, which is mandatory for new and existing ships, and Table B Materials, which is mandatory for new ships and voluntary for existing ships. “These involve a Materials Declaration for all our products containing materials identified by IMO as hazardous, as well as a Declaration of Conformity which confirms that we have the quality processes and procedures we need to ensure the correctness of our Materials Declarations,” note Dr. Holger Gehring and Harald Krekel, who implemented the process for compliance with this convention in MAN Diesel. Having accompanied the development of the new IMO legislation closely through all its stages, MAN Diesel has prepared its response to the changes well in advance and already has its solution in place. “Materials Declarations are already available for all MAN Diesel Products”, Gehring confirms. “In this way, as with our early avail- ability of engines complying with emissions legislation, we aim to give our customers clear future perspectives,” Gehring states. “In fact, due to strict safety at work regulations in Europe, our engines contain only minor proportions of the hazardous substances listed by the IMO convention,” Gehring states. “And in any case, similar declarations are already requested in the “Green Passport” schemes that is run by the Classification Societies,” he adds. Essentially, MAN Diesel has adopted a delegated approach which obliges its suppliers to make parallel declarations. The obligation to declare potentially hazardous substances is now firmly enshrined in our contracts with our suppliers and our Conditions of Purchase. To ensure compliance, we have contacted our suppliers and ascertained what substances PAGE 9 they use. The materials identified are, as stated, in very small amounts – lead in bearings, lead oxide in gaskets and mercury in thermometers. Under our revised conditions and our quality guidelines, suppliers issue MAN Diesel with their own Material Declarations, and are obliged to inform us immediately of proposed changes in their manufacturing practices. Parallel to identification and documentation of hazardous substances, we have investigated how to reduce or even eliminate these substances from our products. As a start, lead-oxide-free gaskets have been intensively tested. Most of the gaskets so far containing lead oxides have been substituted with lead-free components with the same or even better performance. The remainder will follow shortly, when performance testing is finally concluded. Ship recycling in the past has not effectively dealt with hazardous materials from ships. IMO legislation places the onus on ship builders and suppliers, including engine builders and designers, in demanding that all ship components minimise or, where possible, completely eliminate harmful substances. MAN Diesel has already introduced material declarations to comply with this legislation
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