VEM Energy Efficiency in Shipbuilding

VEM GROUP a world full of motion

Energy efficient designs for the ship building industry

Applications and energy efficient solutions, status of submission

VEM distributor for the Netherlands:SERMES NederlandTelefoon : 088-0118000Telefax : 088-0118088e mail : [email protected] prifile on LinkedIn: http://www.linkedin.com/company/sermes-nederland-vem-electric-motors-?trk=top_nav_home


Energy efficient solutions for applications on ships and offshore

•Definitions

•Type testing and construction supervision

•Status of permission

•Examples of markings

•Efficiency classification of ship motors

•Possibilities for increase of efficiency in electric drive technology on board of ships

IE 3IE 3

(IE 1)(IE 1)IE 2IE 2

X


Shown are low voltage motors (LV-motors) as auxiliary drives in applications below and above deck of civil sea-going ships and in industrial offshore applications [Naval ships are liable to different rules and regulations]

Energy efficient solutions for applications on ships and offshore


Important definitions

Operation on deckMotors for „operation on deck“ are designed in type of protection IP 56 without outer fan. As the motors are built without outer fan and cooling is only done by radiation of heat, the output of the motors for continuous operation is reduced approx. 30 to 40% compared to the basic motor series. Operation below deckMotors for „operation below deck“ are designed according to the desired application in -type of protection IP 55 for general use, i.e. machine rooms or -type of protection IP 56 for use in rooms with spray and splash water



Test certificates acc. to DIN EN 10204 (2005) and EN 10204 (2004)

Type of test certificate Content of certificate Confirmation of certificate

2.1 Factory certificate 2.1 Declaration of compliance with the order

manufacturer

2.2 Test report 2.2 Confirmation of compliance with the order by specification of test results from non-specific testing

manufacturer

3.1 Inspection certificate 3.1 Confirmation of compliance with the order by specification of test results from specific testing

The acceptance representative of the manufacturer who is independent of the production department

3.2 Inspection certificate 3.2 The acceptance representative of the manufacturer who is independent of the production department and the acceptance representative commissioned by the ordering party or the acceptance representative named in the official regulations

A manufacturer can include test results in the inspection certificate that are based on specific tests of the used semi finished products, provided that he can assure the traceability and he can produce the corresponding test results.



Drives for essential services

Production according to the required rules of the classification society. For motors up to a certain limit output (depending on classification society) a type test certificate is necessary. Above this limit output individual approval must be arranged. Some classification societies ask for a construction inspection for motors above a certain limit output.Inspection certificate 3.1 acc. to EN 10204,Inspection certificate 3.2 acc. to EN 10204 only for motors above limit output for some classification societies.



Drives for essential services

Production according to the required rules of the classification society. A type test certificate is not necessary and individual testing is done only for motors with certificate.Inspection certificate 3.1 acc. to EN 10204 only for motors with certificate


Rated voltages and frequencies

The basic design allows the following operational voltages and frequencies:

380V, 50Hz440V, 60Hz Voltages and frequencies differing from this only available on request. Motors for outputs, voltages and/or speed ranges outside of the product range included in the special catalogue „Marine applications“ on request.



Overload The motors fulfil the below mentioned requirements of the listed classification societies: ABS no special requirements BV, LRS 160 % rated torque during 15 sGL, RS 160 % rated torque during 15 s. The breakdown torque must not

be reached. DNV 160 % rated torque during 15 s at rated frequency and rated

voltage

DIN EN 60034 1,5-times rated current and rated voltage for 2 min

The rated current is given in the selection tables for rated voltages 380 and 440 V.



Approval, construction inspection, test certificates

The production and approval regulations of the classification societies must be kept during engineering, production and test of the motors. Condition for production permission of the supplied goods is an existing TYPE APPROVAL CERTIFICATE of the classification society.

When applying the manufacturer must proof the qualification of its products by tests, confirmations and material certificates. The test, approval, certification and supply is done according to the corresponding test and approval regulations supervised by the internal quality management or an external auditor of the classification society. Copies of the certificates can be found in the internet: http://www.vem-group.com (see column Infocenter, sector approvals/certificates, topic ship motors). The documents are pdf-files made from the original; they will be regularly updated and therefore they are always the latest edition.




Standards and regulationsThe motors in marine design are built according to the regulations of the classification societies

ABS American Bureau of Shipping, USABV Bureau Veritas, FranceCCS China Classification Society, ChinaGL German Lloyd, GermanyDNV Det Norske Veritas, Norway LRS Lloyds Register of Shipping, GB PRS Polski Rejestr Statkow, PolandRINA REGISTRO ITALIANO NAVALE, ItalyRS Register of Shipping, Russia


Motors protected against sea water acc. to „Bureau Veritas“

http://www.veristar.comCoolant temperature 45 °CThermal class 155 [F]Limit temperature of winding 95 KShaft steel Manufacturer must be approved by BVIndividual approval for essential drives: > 100 kWConstruction inspection for essentialdrives: -Approval mark on the housing of the motor Name plate Marking in English/French; Coolant temperature 45 °C

or different agreed coolant temperature; Marked „MV acc. to BV“.

Type testing and construction inspection



Approved design series:

VEM motors Thurm GmbH

KPR 56 …100; IE*- KPR 56 …100KPER 63 … 112; IE*- KPER 63 … 112

VEM motors GmbH

K10R 112…315K11R 132 … 315IE mark only possible as addition behind type designation Example: K10R 200 L4 IE2 or K11R 315 M2 IE2

Design series / Marking


Motors protected against sea water acc. to „German Lloyd“http://www.gl-group.comCoolant temperature 45 °CThermal class 155 [F]Limit temperature of winding 100 KBearing temperature of friction bearing with special grease 75KIndividual approval for essential drives: ≥ 50 kW for essential installations Construction inspection for essentialdrives: -Name plate Marking German/English; Coolant temperature 45 °C or different agreed coolant temperature;

Marked „SS nach GL“.VEM motors GmbH Wernigerode is authorized to perform the tests in direct responsibility according to the rules of German Lloyd. The certificates issued on this basis will be checked and signed by German Lloyd before approval.



Existing type approvals

Motors protected against sea water acc. to „German Lloyd“


Motors protected against sea water acc. to „German Lloyd“

Approved design series :



VEM motors GmbH

K10R 112…315, IE1-K10R 112 …315K11R 132 … 355, IE1- K11R 132 … 355, IE2-W.1R 132 …355




Motors protected against sea water acc. to „Det Norske Veritas“http://www.dnv.comCoolant temperature 45 °CThermal class 155 [F]Limit temperature of winding 100 KShaft steel S355J2G3 with manufacturers certificate 3.1

of manufacturers approved by DNV Individual approval for essential drives: <100 kW with manufacturers certificate

above 100 kW up to <300 kW DNV approval for shaft manufacturer and manufacturers certificateabove 300 kW DNV approval

Construction inspection for essentialdrives: - Name plate Marking English/French; Coolant temperature 45 °C or different agreed coolant temperature,

Marked „MV acc. to DNV“Text as follows included in the inspection certificate 3.1: “ DNV Rules for Ships, HSLC & MOU, TAC E-6737“



Motors protected against sea water acc. to „Det Norske Veritas“


Motors protected against sea water acc. to „Det Norske Veritas“




VEM motors GmbH

K10R 112…315K11R 132 … 315IE mark only possible as addition behind type designation Example: K10R 200 L4 IE2 or K11R 315 M2 IE2




Motors protected against sea water acc. to „Lloyd’s Register of Shipping“ http://www.lr.org/code/home.htmCoolant temperature 45 °CThermal class 155 [F]Limit temperature of winding 95 KShaft steel: from manufacturers certified by LROS

> 100 kW LR approval certificate 3.2Individual approval for essential drives: ≥ 100 kW Construction inspection for essentialdrives: ≥ 100 kW Name plate: Marking English/French; Coolant temperature 45 °C or different agreed coolant temperature,

Marked „MV acc. to LROS“


Motors protected against sea water acc. to „Lloyd’s Register of Shipping“



Motors protected against sea water acc. to „Lloyd’s Register of Shipping“



KPR 56 …100KPER 63 … 112

VEM motors GmbH

K10R 112…315K11R 132 … 315

IE mark only possible as addition behind type designation Example: KPR 100 L4 IE2 or K11R 315 M2 IE2




Motors protected against sea water acc. to „Russian Maritime Register of Shipping“http://www.rs-head.spb.ruCoolant temperature 45 °CThermal class 155 [F]Limit temperature of winding 105 KIndividual approval for essential drives: > 55 kW Construction inspection for essentialdrives: - Name plate Marking English/RussianCoolant temperature 45 °C or different agreed coolant temperature,

Marked „MV acc. to RS“The quality management of VEM motors GmbH Wernigerode is authorized by the Russian Maritime Register of Shipping to certify the motors based on the Agreement of Supervision No. 99.204.272 and the existing Type Approval Certificate. The test reports must be submitted for approval by the Russian Maritime Register of Shipping.



Motors protected against sea water acc. to „Russian Maritime Register of Shipping“


Motors protected against sea water acc. to „Russian Maritime Register of Shipping“



KPR 56 …100KPER 63 … 112

VEM motors GmbH

K10R 112…315K11R 132 … 315, 355





Motors protected against sea water acc. to „China Classification Society“http://www.ccs.org.cnCoolant temperature 45 °CThermal class 155 [F]Limit temperature of winding 105K for motors ≥ 600 W and for self ventilated

motors (IC410)100K for motors above 600 W

Shaft steel: must be approved by CCS for propulsion motors and drives (if the shaft is part of the drive)

Individual approval for essential drives: > 50 kW for essential installations Construction inspection for essentialdrives: - Name plate: Marking English/FrenchCoolant temperature 45 °C or different agreed coolant temperature,

Marked „MV acc. to CCS“



Motors protected against sea water acc. to „China Classification Society“


Motors protected against sea water acc. to „China Classification Society“



KPR 56 …100KPER 63 … 112

VEM motors GmbH

K10R 112…315K11R 132 … 315




Motors protected against sea water acc. to „American Bureau of Shipping“ http://www.eagle.orgCoolant temperature 50°C for machine rooms

45°C for all other locations Thermal class 155 [F]Limit temperature of winding 95 KIndividual approval for essential drives: ≥ 100 kW Construction inspection for essentialdrives: ≥ 100 kW Name plate Marking German/English

Ambient temperature 45 °C or 50°C or different agreed coolant temperature, Marked „MV acc. to ABS“.

Approval of drawings available for motors up to an output >100 kW; for bigger outputs a separate approval of drawings is necessary for each individual motor. For approval of drawings the following details are necessary (to be supplied by the customer): - Shipyard executing the contract, name, address, building no. from ABS or name of the ship, - What is it, that the motor is driving?




Motors protected against sea water acc. to „American Bureau of Shipping“



Motors protected against sea water acc. to „American Bureau of Shipping“



KPR 56 …100KPER 63 … 112

VEM motors GmbH

K10R 112…315K11R 132 … 315, 355



Motors protected against sea water acc. to „Polski Rejestr Statkow“ http://www.prs.plIf required individual approval via „German Lloyd“ Ambient temperature 45 °CThermal class 155 [F]Limit temperature of winding 95 KIndividual approval for essential drives: ≥ 50 Construction inspection for essentialdrives: - Name plate Marking German/English;

Ambient temperature 45 °C or different agreed coolant temperature, Marked „MV acc. to PRS“.



Motors protected against sea water acc. to „REGISTRO ITALIANO NAVALE“http://www.rina.orgIf required individual approval via „German Lloyd“ Ambient temperature 45 °CThermal class 155 [F]Limit temperature of winding 95 KIndividual approval for essential drives: ≥ 50 Construction inspection for essentialdrives: - Name plate Marking German/English;

Coolant temperature 45 °C or different agreed coolant temperature, Marked „MV acc. to RINA“



Efficiency classification for ship motors

Ship motors in IE1, IE2 or IE3, are there any minimum efficiency requirements?

Why? Coolant temperatures 45° or 50°C

(depending on classification society) no stationary electric network, therefore

MEPS acc. to VO 640/2009 EG no

EFF mark permitted until now no

IE mark permitted yes

Within the European Union there is no legal requirement to use high efficiency motors and premium efficiency motors in the shipbuilding industry.

However the direction for future applications will surely also go for energy efficient solutions.


Where are the applications on board of seagoing ships?

Ventilators in climate control and cooling aggregates

Pumps for oil, fuel used water and fire water

Capstans, mooring winches and lifting gear

Drive for bow thruster

Compressor drives

Ex-Motors for explosion protected areas

Main drive Generator


1. Possibility: Energy efficiency by speed control

Estimation of the Central association electric technology and industry [ZVEI]

• 30 million installed drive units in Germany• only 12 % of these are fitted with energy saving speed control • for more than 50 % a change to speed control is preferable

With electronic speed control approx. 20 to 70% of the energy costs can be saved depending on the application compared to conventional methods. (Biggest saving for quadratic load torque characteristics – fans, pumps)

This estimation can also be applied to the ship building industry.


Example: Pump installationComparison flow control throttle and speed control

Source: FEEI, „Kostensparen mit energieeffizienten Standardmotoren“

1. Possibility: Energy efficiency by speed control


2. Possibility: Use of energy efficient motors

Where is the application useful and where not?

Compared to the use ashore it is advantageous that the decision can be madewithout force for the ship building industry. There are no legal requirements.

Important conditions:

S1 operation or S3, ED > 80%Long operation times

Ventilators in climate control and cooling aggregates

Pumps for oil, fuel used water and fire water

Capstans, mooring winches and lifting gearCompressor drives

Ex-Motors for explosion protected areas

Applications:

XX

XX

XXXX


Example for application – Drives below deck

Fire water pumps Use of energy saving motors is not very useful as only temporarily in operation

IE.xx


Cross flow pump unit for waste water processing, K11R 200L4 KV HW

Cooling water pumps K11R 250M6 TWS

Use water pumps Use of energy saving motors is useful, operation time relevant

IE2, 3IE2, 3



Photo: Passenger ship „AIDA Bella“, Meyer Werft

Emergency fan, Climate control room: Emergency fan, Climate control room: EBPR 71K4 FAN GL FDS-K, EBPR 71K4 FAN GL FDS-K, 0,37 kW, 230 V, 60 Hz 0,37 kW, 230 V, 60 Hz 45°C, S1, IM B3, 1735 r.p.m., th.cl.155, IP55 45°C, S1, IM B3, 1735 r.p.m., th.cl.155, IP55


Emergency fan drive Use of energy saving motors is not very useful as only temporarily in operation

IE.xx


IE.

Drives below deck

Starting air compressor with drive motorK11R 225M6 KV HW , 156 546 0330,00 kW, 400/690 V D/Y BS, 60 Hz 1155 r.p.m., 45°C, IM B35,IP55, th.cl.155(F)Marine design German LloydWithout individual approval Name plate 400/690V 60Hz 30,00kW 450V 60Hz 30,00kWWith cable glands 1xM50 Balancing with half keys

Starting air compressorUse of energy saving motors is not very useful as only temporarily in operation xx


Example for application – Drives above deck

2x BU1V 225M 4 HB NS SMG TWS HW BP45,00/54,00 kW,1470/1770 r.p.m.,45°C, 380/440 V D/D,50/60 Hz, IM V15,IP56,th.cl.180(H), IC 416

Deep sea submarine MARUM QUEST on board of research vessel „Meteor“

Towing winchUse of energy saving motors is not very useful because of duty type, best solution is inverter drive

IE.IE.xx


Towing driveOffshore special ship „MÆRSK LEADER“Anchor Handling Tug / Supply Vessel (AHTS)Combined anchor handling tug/material transport ship

2x K11R 315L 4, 275 kW, 660 V D, 60 Hz, IP 56Brake SFB 160, 2.100 Nm stat. brake torque

Drive motor


IE.IE.xx

Example for application – Drives above deck


BU0U 250M 6, 50,00 kW, 985 r.p.m, 45°C420 V Y, 50 Hz, IM B35, IP56, therm. class 155[F]


IE.IE.xxExample for application – Drives above deck


Explosion-protected drives

Ship and offshore applications

Operational criteria for energy efficiency are in line with standard ship motors. The design in efficiency classesIE1, IE2 and IE3 is possible.

IE1, 2, 3IE1, 2, 3


Do you have Do you have questions?questions?


Energy efficient designs for the Energy efficient designs for the ship building industry ship building industry

Your contact at VEM

Name: Dipl.-Ing. Michael GrunerAddress: VEM motors Thurm GmbH

Äußere Dresdner Strasse 3508066 Zwickau

Phone: +49(0)375 427 114

Fax: +49(0)375 427 616 Email: [email protected]

Name: Dipl.-Phys. Dirk SeehaseAddress: VEM motors GmbH

Carl-Friedrich-Gauß-Str. 138855 Wernigerode

Phone: +49(0)3943 68 3236Fax: +49(0)3943 68 2303Email: [email protected]


www.vem-group.comwww.vem-group.com


VEM motors GmbH

Many thanks for your attentionSee you again at VEM motors


www.sermes.frwww.sermes.fr

VEM distributor for the Netherlands:

SERMES NederlandTelefoon : 088-0118000Telefax : 088-0118088e mail : [email protected]

VEM Energy Efficiency in Shipbuilding

Technology

Transcript of VEM Energy Efficiency in Shipbuilding