WATERJETS PRODUCT GUIDE

Transcription

1 WATERJETS PRODUCT GUIDE

2 Copyright by Wärtsilä Netherlands B.V. All rights reserved. No part of this booklet may be reproduced or copied in any form or by any means (electronic, mechanical, graphic, photocopying, recording, taping or other information retrieval systems) without the prior written permission of the copyright owner. THIS PUBLICATION IS DESIGNED TO PROVIDE AN ACCURATE AND AUTHORITATIVE INFORMATION WITH REGARD TO THE SUBJECT-MATTER COVERED AS WAS AVAILABLE AT THE TIME OF PRINTING. HOWEVER,THE PUBLICATION DEALS WITH COMPLICATED TECHNICAL MATTERS SUITED ONLY FOR SPECIALISTS IN THE AREA, AND THE DESIGN OF THE SUBJECT-PRODUCTS IS SUBJECT TO REGULAR IMPROVEMENTS, MODIFICATIONS AND CHANGES. CONSEQUENTLY, THE PUBLISHER AND COPYRIGHT OWNER OF THIS PUBLICATION CAN NOT ACCEPT ANY RESPONSIBILITY OR LIABILITY FOR ANY EVENTUAL ERRORS OR OMISSIONS IN THIS BOOKLET OR FOR DISCREPANCIES ARISING FROM THE FEATURES OF ANY ACTUAL ITEM IN THE RESPECTIVE PRODUCT BEING DIFFERENT FROM THOSE SHOWN IN THIS PUBLICATION. THE PUBLISHER AND COPYRIGHT OWNER SHALL UNDER NO CIRCUMSTANCES BE HELD LIABLE FOR ANY FINANCIAL CONSEQUENTIAL DAMAGES OR OTHER LOSS, OR ANY OTHER DAMAGE OR INJURY, SUFFERED BY ANY PARTY MAKING USE OF THIS PUBLICATION OR THE INFORMATION CONTAINED HEREIN.

3 Wärtsilä Waterjet Product Guide Introduction Introduction This Product Guide provides data and system proposals for the early design phase of waterjet installations. For contracted projects specific instructions for planning the installation are always delivered. Any data and information herein is subject to revision without notice. Issue 1/2017 1/2015 2/2014 1/2014 1/2013 Published Updates "Ship design considerations" modified. Shaft to waterline position changed. Chapters added. Main data updated Chapter "Drawings" added, main data updated First issue of PG Waterjets January 2017 Wärtsilä Marine Solutions Wärtsilä Netherlands B.V. T: +31 (0) P.O. Box BB, Drunen The Netherlands waterjets@wartsila.com Scan this QR-code using the QR-reader application of your smartphone to obtain more information. Wärtsilä Waterjets Product Guide - a4-16 January 2017 iii

4 Table of contents Wärtsilä Waterjet Product Guide Table of contents 1. Modular Waterjet Waterjet Principle of Operation Waterjet thrust Influence of ship parameters on waterjet thrust, jet selection and size Influences on the average inlet speed (v i ) Effects of variations in the average inlet speed (v i ) Computational Fluid Dynamics Wärtsilä Design Method and Philosophy Design method Philosophy Efficiency Economy Environment Description Inlet duct Impeller and shaft line Stator bowl assembly Water-lubricated bearing Jetavator and reversing plate Shaft seal Thrust bearing block Lubrication system Hydraulic system Wärtsilä axial waterjet technology Customized design Standard scope of supply Wärtsilä standard supply layout Not in scope of supply of Wärtsilä Waterjet Size Selection Introduction Size selection for a given engine power Size selection for a given resistance Waterjet Component Selection Introduction Thrust bearing selection Thrust bearing size selection Installation notes for TBB Thrust bearing oil lubrication and cooling pack (LOP) Standard oil lubrication and cooling set Dimensions and general arrangement Booster waterjet lubrication Installation notes for LOP Shaft seal Seal selection Installation notes for shaft seal Hydraulic System Jet hydraulic systems Standard hydraulic power pack (HPP) iv Wärtsilä Waterjets Product Guide - a4-16 January 2017

5 Wärtsilä Waterjet Product Guide Table of contents Dimensions and general arrangement drawings PTO pump data Installation notes for HPP Design Considerations Ship interfacing Ship design considerations Propulsion Control System Propulsion Control System overview Propulsion Control Unit Remote control stations Lever control unit Side displays Control transfer between remote control stations Control system layout Basic four steering/reversing waterjet system Basic two steering/reversing waterjet system Basic two steering/reversing and booster waterjet system Functional description Basic system description Basic main control features Extended main control features Control modes Back-up control (non follow-up control) Indication Anti collision (optional) Cavitation control (optional) Clutch control Prime mover control Slow down request Pump control Alarming Interfaces to non propulsion machinery (external systems) Voyage Data Recorder (VDR) Joystick System (JS) Integrated Automation System (IAS) Installation Electrical installation Power supply Mechanical installation Main Data Waterjet dimensions and weights Drawings List of Drawings Product Guide Attachments Annex Unit conversion tables Prefix Wärtsilä Waterjets Product Guide - a4-16 January 2017 v

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7 Wärtsilä Waterjet Product Guide 1. Modular Waterjet 1. Modular Waterjet With this Product Guide it is possible to make a first jet size selection and to check weights and dimensions of waterjets and possible subsystems. For the modular waterjets the hydrodynamic design of the inlet duct is made by Wärtsilä and it is built by the shipyard as part of the ship construction. Auxiliary systems for the whole waterjet range can be selected with this Product Guide, based on the vessel design details. The largest waterjet in our order book is a 26,000 kw LJX2180 unit. Our design capability goes up to 50 MW. Fig 1-1 Modular waterjet Wärtsilä Waterjets Product Guide - a4-16 January

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9 Wärtsilä Waterjet Product Guide 2. Waterjet Principle of Operation 2. Waterjet Principle of Operation The thrust produced by a waterjet is generated from a water flow that is accelerated in between the entrance at the inlet duct and exit at the nozzle. The figure illustrates this in its most basic form. Water from underneath the hull flows into the jet inlet duct. The dividing streamline indicates what part of the flow is entering the inlet duct and what part of the flow is passing by. Fig 2-1 Waterjet flow 2.1 Waterjet thrust We can calculate the waterjet thrust when entrance speed (v i ), exit speed (v j ) and volume flow are known. Take for example an average entrance speed (v i ) into the jet at 20 m/s, an exit speed (v j ) at the nozzle of 40 m/s and a volume flow (v) of 3 m 3 /s. From the volume flow and the specific density of sea water, the mass flow through the system is calculated. In this case 3 m 3 /s x 1025 kg/m 3 = 3075 kg/s. The thrust generated by the system can be calculated with Isaac Newton s formula; Force equals mass x acceleration [F=ma]. For our example using the mass flow and the speed difference over the system in the derived formula this results in F= 3075 (40-20) = N or 61 kn. 2.2 Influence of ship parameters on waterjet thrust, jet selection and size It is impossible to give generic performance data for a waterjet without considering the ship parameters. The most important effects will be explained in the next paragraphs Influences on the average inlet speed (v i ) There are three main parameters influencing the speed of the water flow (v i ) entering the jet system: ship speed (1), the wetted length of the hull in front of the jet intake duct (2) and the location of the dividing streamline (3). 1 The relation of the inlet speed v i with the ship speed is obvious. The faster a ship moves through the water, the faster water will flow along the hull and v i will vary in a relative direct relation with the ship speed. 2 The relation of v i with the wetted hull length in front of the intake duct (= ship waterline length minus the length of the jet inlet duct) is relatively simple as well. A longer Wärtsilä Waterjets Product Guide - a4-16 January

10 2. Waterjet Principle of Operation Wärtsilä Waterjet Product Guide wetted length results in a longer frictional path of the water flowing along the hull resulting in a relatively lower v i for a longer hull and a higher v i for a shorter hull. 3 The relation of v i to the location of the dividing streamline is mainly determined by the size and power density of the jet pump. A large pump with a high power density demands a high flow resulting in a relative higher suction depth and thus a deeper located dividing streamline. Due to the variation in speed over the ship s boundary layer resulting from the friction with the hull, the average v i will decrease or increase with a deeper or more shallow location of the dividing streamline Effects of variations in the average inlet speed (v i ) The first main effect of a variation in v i downstream is seen with the pressure build up in front of the impeller. Depending on the ship speed, v i is usually more than the pump requires. This means the water enters the inlet faster than the pump can pump out. The kinetic energy of the flow entering the system is transformed by the inlet duct into potential energy or pressure build up in front of the impeller. This pressure build up is referred to as the Net Positive Suction Head Available; NPSH(A). The NPSH(A) in front of the impeller will partly determine the cavitation margins of a certain ship/jet application. The ships wetted length is thus a parameter of importance for predicting the cavitation behavior of a jet in a certain vessel and must be known during the jet selection process. The second main effect of a variation in v i downstream is the variation of the average jet speed (v j ) at the exit nozzle of the system. The relation between the intake and jet nozzle speed is however not linear. A lower v i will result in a lower v j, but the decrease of v j will be relatively much smaller than the decrease of v i. A lower v i thus increases the acceleration of the mass flow over the system and by that increases the thrust generated by the system. 2.3 Computational Fluid Dynamics Analyses of the flow through the waterjet inlet are made with a Computational Fluid Dynamics (CFD) inlet analysis tool. The tool is based on a commercial CFD software program and a fully automated in-house made 3D mesh generator. The commercial CFD code can solve the Reynolds Averaged Navier-Stokes equations for any three dimensional geometry. Wärtsilä has extensive knowledge in the interaction of ship hulls and waterjet inlets. For over 20 years CFD is used to analyse hull/inlet interaction to determine the best performing inlet geometry. Fig 2-2 CFD calculation 2-2 Wärtsilä Waterjets Product Guide - a4-16 January 2017

11 Wärtsilä Waterjet Product Guide 3. Wärtsilä Design Method and Philosophy 3. Wärtsilä Design Method and Philosophy 3.1 Design method State of the art engineering tools are used within Wärtsilä to make designs and manage the product data. A global Product Data Management (PDM) system with integration of 3D design software is the backbone of the engineering tools. The PDM system manages the engineering data like 3D CAD models, (production) drawings and technical documents, but also the Bill of Materials (BoM) for each order. This ensures the right data is connected to the right order. The benefits are an accurate and efficient production process, the availability of product data throughout the life cycle of the product (e.g. for spare parts), and the ability to keep orders attached to product management and developments. The fact the system is global means that each user can make use of the vast Wärtsilä knowledge and data. The 3D setup in the system, where the PDM Bill of Materials dictates the assembly, means that the complete assembly is already checked in the system during design. The 3D data is also used in the production process for the complex 3D machining of components. The same 3D models are used in downstream engineering tools like the Finite Element Method (FEM) program, or the Computation Fluid Dynamics (CFD) program. 3D models of the waterjet can be exported in various formats (e.g. STEP), to allow the customer to import our design into their cad design of the vessel. This will clarify the location of the waterjet unit and may prevent interface issues with the vessel s structure or other positioned components. Fig 3-1 PDM utility Designs are evaluated with the FEM tool. All real life load cases can be simulated to determine the behavior of the components and assess their suitability for use. This is the normal way of working for Wärtsilä development engineering. The tool has been an integral part of the design process of the Wärtsilä waterjet as well. This allowed us to use materials and their properties optimally in the final designs of the components. 3.2 Philosophy The key for a good propulsor is of course to generate as much thrust as possible from the input power. Equally important is the mechanical integrity of the product. The requirement is an excellent performing propulsor that keeps performance over its life time. The philosophy can be viewed from three angles Wärtsilä Waterjets Product Guide - a4-16 January

12 3. Wärtsilä Design Method and Philosophy Wärtsilä Waterjet Product Guide Efficiency Economy For efficiency optimal hydrodynamic performance is required. In general, so also for the Midsize waterjet, this is assured using CFD analysis and model scale testing. The actual structure is moulded around this hydrodynamic shape, using FEM and other analysis to assure strength and endurance. The hydrodynamic performance and technology of the Modular waterjets has proven itself in applications with powers ranging from 1200 kw to kw. Wärtsilä looks in two ways to economy; it is delivering a cost effective product, but equally important, it is also about the total cost a customer has to make, both in installation and in the life time, where often a lot of cost can be saved. For the yard this means work is to be minimized. This is why the Midsize is a pre-installed unit, so no assembly of major parts or aligning procedures during the installation are required. Also the electrical connections are pre-wired on the unit, and the controls are commissioned in the factory to save valuable commissioning time on that part during vessel commissioning. We can give many examples of life time cost considerations. A few examples are; The use of stainless steel for the most demanding parts that determine the (enduring) performance. The inboard bearing layout is designed for endurance. Wear parts are designed to be easily replaceable without docking (saving operators time and money), and scheduled maintenance is centered around normal ship docking intervals. Details on the components and how they contribute to this philosophy can be found in the next chapter Environment In consideration of the environment we have been able to avoid using oil in the stator bowl or outboard for the Midsize waterjet. Details on the components and how they contribute to this philosophy can be found in the next chapter. 3-2 Wärtsilä Waterjets Product Guide - a4-16 January 2017

13 Wärtsilä Waterjet Product Guide 4. Description 4. Description This chapter describes in brief the main components and features of the waterjet. The waterjet installation consists of an impeller, a stator bowl, an inboard thrust bearing block, a shaft seal, and a seat ring. Waterjets are equipped with a steering device, called jetavator (brief for jet deviator). Mounted behind the stator bowl this jetavator can deflect the jet stream sideways to create a steering force. The jetavator also contains the reversing equipment to create astern thrust. Fig 4-1 Booster waterjet Fig 4-2 Waterjet with steering and reversing capability Wärtsilä Waterjets Product Guide - a4-16 January

14 4. Description Wärtsilä Waterjet Product Guide 4.1 Inlet duct During operation, water enters the waterjet installation through the inlet duct, which is a part of the ships construction. After passing the impeller, rotation in the flow is removed and the water is accelerated in the stator bowl. This creates the thrust necessary to propel the ship. Each waterjet is driven by a main engine through a gearbox with a clutch. The clutch makes it possible to start the prime mover without driving the impeller shaft. The impeller shaft is supported inside the ship by a thrust bearing block and outside the ship in the stator bowl by a water lubricated bearing. A shaft seal prevents water from entering the ship. The inlet duct is an integrated part of the hull and is built by the shipyard according to the inlet hydraulic profile drawing of the inlet duct, supplied by Wärtsilä. The inlet duct is designed to give minimal losses and to ensure a high overall efficiency of the waterjet installation. The inlet duct has to be equipped with an inspection hatch through which debris, clogging the pump impeller, can be removed. For maintenance work the shaft can be supported through the inspection hatch. 4.2 Impeller and shaft line The impeller rotates inside the stainless steel seat ring. The impeller is hydraulically fitted on the shaft. A shaft sleeve is mounted on the rear end of the shaft, protecting the shaft from wear caused by running in the water lubricated bearing. 4.3 Stator bowl assembly The stator bowl is located behind the seat ring. The stator bowl eliminates the rotational component from the water flow leaving the impeller and is equipped with an integrated nozzle to accelerate the flow. This increases overall performance of the waterjet. The stator bowl also acts as the support for the water-lubricated bearing Water-lubricated bearing The use of a water-lubricated bearing in the stator is beneficial for the environment and enhances the reliability and maintainability of the waterjet. The standard bearing used in Wärtsilä waterjet systems consist of a stainless steel bush with a composite lining. Replacement of the water lubricated bearing can be done with the vessel afloat. 4.4 Jetavator and reversing plate For steerable waterjets, the jet stream is deflected by a jetavator which is mounted behind the stator bowl. The jetavator is actuated by two hydraulic cylinders. The jetavator can be turned 30 to port and 30 to starboard. The jetavator contains a hydraulically activated reversing plate through which part or all of the jet stream can be deflected forward. The reversing plate can be gradually moved, which makes it possible to vary the thrust from full ahead via the zero thrust position to full astern and vice versa. The reversing plate must be in the zero thrust position before the impeller shaft is clutched in. The zero thrust position prevents the ship from moving when the impeller shaft is rotating. The reversing cylinder is equipped with a counter balance valve (load holding valve). This safety device keeps the reversing plate movement controllable and prevents that, in the event of a hose failure, the reversing plate moves to full astern without control. 4-2 Wärtsilä Waterjets Product Guide - a4-16 January 2017

15 Wärtsilä Waterjet Product Guide 4. Description 4.5 Shaft seal Steering and reversing are activated by the control system. The position of the jetavator and the position of the reversing plate are fed back to the control system, via position sensors inside the hydraulic cylinders. The sterntube seal is an elastomer based radial face type seal with split components and an inflatable emergency seal to close the stern tube in case of a seal failure and to facilitate servicing of the seal while the vessel is afloat. Fig 4-3 Shaft seal The seal is specifically designed for high speed operation and offers a robust and reliable solution, even when operating in shallow or dirty waters. The seal is lubricated and cooled with a forced water flow from the ships cooling system. 4.6 Thrust bearing block The thrust bearing block (TBB) is located inside the ship. The location inside the ship enables good maintainability, and allows the use of large size bearings for increased operating life time. The TBB has two mounting flanges, which are bolted to the ships foundation. It supports the shaft and transmits the axial thrust coming from the impeller to the ship. The TBB contains a double row spherical roller bearing and a spherical roller thrust bearing, which are positioned to have a common pivot point. The block is sealed by means of two lip seals running on the bearing bush. The TBB has forced lubrication, which is also used for cooling. Inside the bearing housing there is a standpipe on the return line, which ensures there always is an oil bath in the housing, independent of the functioning of the lubrication system. In case of a malfunction of the lubrication system, the oil level in the thrust bearing block and the cooling capacity of the TBB are sufficient for operation at reduced rpm. Wärtsilä Waterjets Product Guide - a4-16 January

16 4. Description Wärtsilä Waterjet Product Guide Fig 4-4 Sectional view of thrust bearing Fig 4-5 Thrust bearing 4.7 Lubrication system The lubrication system consists of a tank, a cooler, a filtration unit and a separate pump unit. The pump unit must be placed as close to the thrust bearing block as possible, and below the oil outlet of the thrust bearing block. For steerable/reversible waterjets, the lubrication tank is integrated in the hydraulic powerpack as a standard. A booster waterjet always has a seperate lubrication tank. The lubrication system is equipped with the following safety devices and alarms: A pressure alarm to detect whether the lubrication system is available. A PT-100 temperature sensor placed in the thrust bearing block to monitor oil temperature. The signal is used in the control system to give alarm signals when needed. A clogging alarm on the filter. A low level alarm for the lubrication unit. Fig 4-6 Lubricating oil tank for a booster waterjet 4-4 Wärtsilä Waterjets Product Guide - a4-16 January 2017

17 Wärtsilä Waterjet Product Guide 4. Description 4.8 Hydraulic system The hydraulic system consists of a variable displacement main pump, a power pack with a secondary pump and the hydraulic cylinders on the waterjet. The system is a load sensing system to reduce the losses to a minimum. This allows for a small tank. The oil is purified by a return filter. Proportional directional valves on the power pack supply the required pressurized oil to the steering cylinders and the reversing cylinder. The proportional valves get their input signals from the control system. The sensor signals are transfered to the control system and/or the central alarm system. For cooling, back up, start-up and test situations an electrically driven hydraulic pump is available on the hydraulic power pack. Fig 4-7 Hydraulic power pack 4.9 Wärtsilä axial waterjet technology Wärtsilä axial waterjets are a line of single stage compact high performance waterjets combining mixed flow properties with an axial build. The result is a much reduced vessel transom occupation with highly increased waterjet cavitation margins for optimum vessel operating flexibility. The reduced transom occupation is achieved without reduction of the inlet duct diameter and waterjet pump size in order to maintain maximum efficiency for lowest fuel consumption. Average 25% reduced transom occupation Jet sizes are indicated by the front side diameter of the impeller seat ring. Unlike a non-axial design (Figure 4-8, left), the Wärtsilä axial design waterjet (Figure 4-8, right) does not expand in radial direction downstream. The flow into the jets is guided through the pump along the most efficient path, while at the same time the transom mounting flange diameter is reduced. This will allow much easier fitting of the jet in the desirable space both in width and in height. For naval architects this creates the possibility to apply a larger power density onto narrower hulls for achieving top vessel performance. Wärtsilä Waterjets Product Guide - a4-16 January

18 4. Description Wärtsilä Waterjet Product Guide Fig 4-8 Non-axial vs axial dimensions Average 10% higher shaft speed = 10% less torque Compared with non-axial designs for the same jet size, the shaft speed of the impeller is on average 10% higher. This is achieved by the impeller shape having a large blade surface area within small radial dimensions. The lower torque the direct result of the higher shaft speeds - results in both weight and cost savings for couplings, intermediate shaft lines, shafts in general and gearboxes. Up to 15% lower weight The reduced transom size not only results in reduced dimensions, but also gives a substantially lower weight of the installation. Combined with our welded jet construction, this permits further weight optimizations and savings that can be as high as 15% compared to non-axial jet designs for the same inlet diameter. Since waterjet weight at the very end of the vessel is usually difficult to compensate elsewhere in the ship, jet weight savings can result in improved trim of the vessel. Furthermore weight savings will deliver an increase in payload within the same vessel design. Large margins for operating flexibility and manoeuvring The pump cavitation margins are increased by at least 35% compared to the non-axial design for the same inlet dimensions. Thanks to this increase in cavitation margin and the lower impeller tip speed, more power can be allowed onto the pump during manoeuvring resulting in a 15% higher manoeuvring thrust and faster response on acceleration. Also more power will be available to overcome changing operating conditions like vessel resistance increase due to shallow water effects. Furthermore, thanks to the additional cavitation margin, operation with a reduced number of shaft lines is possible at higher loads of the associated prime movers, resulting in better operating flexibility. Black smoke reduction - marginal increase in power absorption at manoeuvring During manoeuvring the Diesel engine operates in its critical zone, while in this area waterjets tend to absorb increased power for lower impeller speeds. The result can be a high load for the engine, resulting in smoke and an increased thermal load. For the Wärtsilä axial jet series this unwanted increase in power absorption is up to 70% lower than that of competing non-axial designs. Design layouts All jet designs are available in a steering/reversing (SR), inboard hydraulics (SRI) and booster (B) execution. On request we can offer solutions for special applications e.g. reversing only (R), steering only (S) and thrust in all directions (360 ). The key benefits of the axial technology will be valid for all executions. 4-6 Wärtsilä Waterjets Product Guide - a4-16 January 2017

19 Wärtsilä Waterjet Product Guide 4. Description Fig 4-9 INLS system for the US Navy equipped with custom designed jets for thrust in all directions (360 revolving jet nozzle fitted) 4.10 Customized design Over the years several special designs have been developed based on customer request for specific applications. Examples of these are: Inboard hydraulic systems bringing hydraulic cylinders and hoses inside the vessel (figure 4-10), shock proof and fast crash stop installations for Naval use (figure 4-11), and installations providing thrust in all directions (figures 4-9 and 4-12). With Wärtsilä'slarge experience and engineering skills (ranging from controls, to analasys, to mechanical), special requirements can be implemented for new projects as well. Fig 4-10 Inboard hydraulic system Wärtsilä Waterjets Product Guide - a4-16 January

20 4. Description Wärtsilä Waterjet Product Guide Fig 4-11 Shock proof fast crash stop jet for Naval use Fig degree rotatable jet 4.11 Standard scope of supply Wärtsilä standard supply layout The standard scope of supply includes the following: Waterjet assembly Seat ring Impeller shaft assembly Shaft seal Thrust bearing Hydraulic power pack Lubricating and cooling set Bolting for connection of waterjet and seat ring Bolting for thrust bearing block Other scope of supply can include: 4-8 Wärtsilä Waterjets Product Guide - a4-16 January 2017

21 Wärtsilä Waterjet Product Guide 4. Description Control system Jet inlet duct - design and fabrication Power transmitting components between impeller shaft and gearbox Connection of the jet with the ship Customized connection of 3rd party outboard hydraulic system to Wärtsilä powerpack Waterjet inlet duct Wärtsilä designs the hydraulic profile of the jet inlet duct for every project. Good jet inlet duct design results in optimum efficiency and avoidance of undesirable cavitation effects at the inflow of the pump. The yard is responsible for the structural design and manufacturing of the jet inlet duct based on the hydraulic profile supplied by Wärtsilä. For the construction of the inlet duct normally the same material is used as for the hull. For the inlet duct design, the ship s hull lines are required in 3D Siemens NX, IGES, STP or Parasolid electronic format. A standard questionnaire of the information required can be found in the attachments of this product guide. A digital version of this questionnaire can be downloaded from the Wärtsilä website Shaft connection between jet and gearbox Inboard, directly forward of the stern tube, the impeller shaft is supported by a self-aligning oil-lubricated combined axial and radial roller bearing. The free end of the shaft is machined for fitting of a hydraulic type coupling. The hydraulic coupling and power transmitting components to the gearbox flange can be supplied as an option. Most common options include geartooth coupling, flexible disc packages in combination with hollow steel shafts, or composite shafts Electrical insulation Bolting It is advised to electrically isolate the stainless jet construction from the ship s hull if the ship hull is not built from reinforced plastics. To prevent galvanic corrosion and interaction, the following is included in each scope of supply: Several sacrificial anodes mounted on the outside of the waterjet construction. One insulating gasket between waterjet seat ring and the transom. One insulating gasket between seal group and sterntube. Synthetic bushes and rings for all mounting bolts. Current collectors for the jet impeller shaft. An insulation plate between the jet shaft and the intermediate shaftline (if applicable). Insulation at the manifold block. To complete the insulation the yard needs to supply/take care off: Chockfast Orange between the inboard thrust bearing block and the hull. Insulating hoses to connect to thrust bearing block. Insulating pipes or hoses to connect to the manifold block on top of thewaterjet assembly. For the following connections, bolts are supplied by Wärtsilä: Between stator bowl, seat ring and transom, executed in stainless steel. Between thrust bearing block and foundation. Wärtsilä Waterjets Product Guide - a4-16 January

22 4. Description Wärtsilä Waterjet Product Guide Between seal and sterntube, executed in stainless steel Not in scope of supply of Wärtsilä The Wärtsilä scope of supply does not include: Structural design and supply/fabrication of the required waterjet inlet duct. Installation of the waterjets on board. Installation and wiring of the control system. Piping and wiring to be done on-board and relevant materials. Piping to outboard connection block. Bolting to be done on board except as noted in above paragraph. Oil for first filling. Prime mover speed governors. Starters for electric motors. Torsional, axial vibration analysis calculation (engine supplier). Shaft alignment and whirling calculations. Cable and pipe glands for transom throughput Wärtsilä Waterjets Product Guide - a4-16 January 2017

23 Wärtsilä Waterjet Product Guide 5. Waterjet Size Selection 5. Waterjet Size Selection 5.1 Introduction The thrust generated by a waterjet is the reaction on the acceleration of the flow from the average intake speed v i at the inlet to the exit speed v j at the nozzle. This is illustrated in figure 5-1. Fig 5-1 Waterjet flow The speed at the inlet v i is less than the ship speed and is a function of the length of the ship and the flow through the unit. This affects both the efficiency of the jet and the maximum power which can be applied to the unit for the application. NOTE Please note that the jet selection and performance parameters can only be accurately determined based on ship design, engine and gearbox details. All graphs are for reference only. Do not hesitate to contact Wärtsilä for optimized selections based on your unique ship design. To provide us with the necessary information, the waterjet selection questionnaire can be used. This questionnaire can be found in chapter 10. Drawings. Wärtsilä Waterjets Product Guide - a4-16 January

24 5. Waterjet Size Selection Wärtsilä Waterjet Product Guide 5.2 Size selection for a given engine power Figures 5-2 and 5-4 are used to select the proper waterjet size when the installed power per jet is known. First a correction factor is determined with aid of figure 5-2. The minimum waterjet size is then determined with aid of figure 5-4. The figures are based on transmission losses of 3%. Fig 5-2 Power factor Fig 5-3 Power factor (cont.) 5-2 Wärtsilä Waterjets Product Guide - a4-16 January 2017

25 Wärtsilä Waterjet Product Guide 5. Waterjet Size Selection Fig 5-4 Size selection based on power Fig 5-5 Size selection based on power (cont.) Wärtsilä Waterjets Product Guide - a4-16 January

26 5. Waterjet Size Selection Wärtsilä Waterjet Product Guide 5.3 Size selection for a given resistance Figures 5-6 and 5-8 are used to select the proper waterjet size when the resistance of the ship is known. First a correction factor is determined with aid of figure 5-6. Finally, the minimum waterjet size is determined with aid of figure 5-8. Fig 5-6 Resistance factor Fig 5-7 Resistance factor (cont.) 5-4 Wärtsilä Waterjets Product Guide - a4-16 January 2017

27 Wärtsilä Waterjet Product Guide 5. Waterjet Size Selection Fig 5-8 Selection based on resistance Fig 5-9 Selection based on resistance (cont.) For a list of main dimensions for available waterjet sizes, refer to chapter 9. Main Data. NOTE Please note that the jet selection and performance parameters can only be accurately determined based on ship design, prime mover and gearbox details. All graphs are for reference only. Do not hesitate to contact us for optimised selections based on your unique ship design. Wärtsilä Waterjets Product Guide - a4-16 January

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29 Wärtsilä Waterjet Product Guide 6. Waterjet Component Selection 6. Waterjet Component Selection 6.1 Introduction The waterjet installation consists of various subsystems and components. It contains: A hydraulic system to generate hydraulic pressure for steering and reversing actions. A lubrication system to generate adequate lubrication and cooling for the TBB. A Waterjet Control Unit (WCU) that interacts between the various waterjet components, engine room and the Bridge Control Station. A feedback unit, that collects and converts the signal from the sensors in the steering and reversing cylinders and transmits them to the WCU. An overview of the complete waterjet installation is given in figure 6-1. The connections to and between the various components (pipes, hoses,cables, etc.) are yard supply. Fig 6-1 Waterjet system overview In the previous chapter a waterjet size selection has been made based on the selection graphs. In the next paragraphs the following components will be selected: Thrust bearing block Lubrication pump Lubrication tank (booster waterjet only) Shaft seal PTO pump Hydraulic Power Pack (Steerable / reversible only) 6.2 Thrust bearing selection One of the key benefits for any waterjet design is an inboard position of the thrust bearing. It increases reliability and maintainability of the system. The cylindrical outer contour of the Wärtsilä Waterjets Product Guide - a4-16 January

30 6. Waterjet Component Selection Wärtsilä Waterjet Product Guide impeller makes the impeller insensitive to axial movements and optimum tip clearance is always guaranteed, even with the thrust bearing not placed in the direct vicinity of the impeller. The thrust bearing is executed as a self-aligning, oil-lubricated combined axial and radial roller bearing mounted on a hollow sleeve and is equipped with integrated PT100 sensor. The hollow shaft sleeve is also used to locate the impeller shaft assembly in axial and radial direction. In standard configuration, the bearing housing is made of aluminium for minimum weight. For installations delivered for shock requirements, the housing is made of steel. Due to its position inside the ship, the bearing can easily be oversized without affecting the dimensions and performance of the water jet stator bowl. The mounting flanges of the thrust bearing are connected to the ship structure with cast resin, such as Chockfast Orange, (yard supply) and fasteners (Wärtsilä supply) as a standard Thrust bearing size selection For preliminary design purposes it is possible to select the thrust bearing size from table 6-1 based on the jet size selected in section 5.2 or 5.3 above. Fig 6-2 Table 6-1 Thrust bearing main dimensions Thrust bearing selection and main thrust bearing data Jet size Thrust bearing size Block dimensions (l*w*h [mm]) Oil contents [ltr] Dry weight [kg] (Al execution) *460* *554* (integr. sump) *600* *600* *720* *880* *880* *880* *880* Wärtsilä Waterjets Product Guide - a4-16 January 2017

31 Wärtsilä Waterjet Product Guide 6. Waterjet Component Selection Jet size Thrust bearing size Block dimensions (l*w*h [mm]) Oil contents [ltr] Dry weight [kg] (Al execution) *1160* *1160* *1160* *1420* *1420* *1650* *1650* Special 2350 Special At order stage, the confirmed size of the thrust bearing will be determined based on all final design details. Final selection may be influenced by for example the vessels operating profile or shock requirements. Please do not hesitate to consult us in case you require more information Installation notes for TBB The thrust bearing block, located inboard, supports the shaft and bears the axial thrust generated by the impeller. The TBB has two mounting flanges, which are bolted to the ships foundation. The foundation shall be constructed to accommodate the position of the thrust bearing block and withstand the forces that act upon it, whilst fulfilling the relevant rules of the applicable classification society. For (dis)mounting and maintenance purpose, significant clearance at several positions of the thrust bearing block is required. Dimensional drawings of these clearances can be found in chapter 9. Main Data of this product guide. 6.3 Thrust bearing oil lubrication and cooling pack (LOP) For each waterjet one thrust bearing oil lubrication & cooling set is delivered. In the event of an accident this oil circuit is protected from sea water pollution by the fact that it is located inboard and, in case of steerable reversible jets, by being completely separate from the hydraulic oil circuitry Standard oil lubrication and cooling set As a standard the separate double oil pump set of the lubrication system is driven by an electric motor. The first pump takes suction from the lube oil reservoir and supplies the oil via a filter and a seawater cooler to the thrust bearing housing. The second pump returns the oil from the thrust bearing to the reservoir. For steerable reversible waterjets the lube oil is stored in a dedicated compartment of the hydraulic power pack. The lube oil filter and cooler are mounted on that compartment. In the unlikely event that the electric motor fails, operation of the jet is still possible at reduced main engine rpm. The maximum rpm at which operation without forced lubrication can take place will depend on the installed bearing size and the prevailing operating conditions. The rpm has to be further reduced in case the maximum allowable operating temperature of the bearing is reached. The standard components of the oil lubrication & cooling set are: Wärtsilä Waterjets Product Guide - a4-16 January

32 6. Waterjet Component Selection Wärtsilä Waterjet Product Guide Double gear pump and electric motor unit (separate). Oil tank with level switch and dip stick (integrated in hydraulic powerpack for steerable waterjets). Filter with bypass and pressure switch (mounted on the tank) at pressure side of the first section of the pump. Fill, drain plug and silica breather (mounted on the tank). Seawater resistant heat exchanger (mounted on the tank). Oil temperature switch (mounted on the thrust bearing) Dimensions and general arrangement If the waterjet size has been selected, the required oil lubrication & cooling set can be selected. General arrangement drawings in.dxf/.dwg format can be submitted via on request or downloaded via a customer section on the Wärtsilä website. The principal dimensional and performance data of pump sets for the standard LOP & cooling sets for 50 Hz 380V supply with IEC frame motor and for 60 Hz 460 V with NEMA frame motor are listed in the tables below. Fig 6-3 Table 6-2 Lubricating oil pump main dimensions 50 Hz Lubricating oil pump set selection and main dimensional and connection data Lube oil pump sets 50 Hz 380 V IEC Frame system data block Jet size 50Hz Pump set Power [kw] I nom [A] I start [A] l [mm] w [mm] h [mm] mass [kg] Cooling water 1 [l/min] 510 LA LB LB LB LB LB LB LB LC Wärtsilä Waterjets Product Guide - a4-16 January 2017

33 Wärtsilä Waterjet Product Guide 6. Waterjet Component Selection Lube oil pump sets 50 Hz 380 V IEC Frame system data block Jet size 50Hz Pump set Power [kw] I nom [A] I start [A] l [mm] w [mm] h [mm] mass [kg] Cooling water 1 [l/min] 1300 LC LC LC LC LC LE LE Connections on the tank. Table Hz Lubricating oil pump set selection and main dimensional and connection data Lube oil pump sets 60 Hz 460 V NEMA Frame system data block Jet size 60Hz Pump set Power [kw] I nom [A] I start [A] l [mm] w [mm] h [mm] mass [kg] Cooling water 1 [l/min] 510 LA LA LA LA LB LB LB LB LB LB LB LB LB LB LD LD Wärtsilä Waterjets Product Guide - a4-16 January

34 6. Waterjet Component Selection Wärtsilä Waterjet Product Guide Lube oil pump sets 60 Hz 460 V NEMA Frame system data block Jet size 60Hz Pump set Power [kw] I nom [A] I start [A] l [mm] w [mm] h [mm] mass [kg] Cooling water 1 [l/min] Connections on the tank Booster waterjet lubrication A booster waterjet does not have a hydraulic power pack in which the lubrication oil can be integrated. This execution requires a separate lubrication and cooling set. The standard components for this system are the same as stated in section Standard oil lubrication and cooling set above. The principal dimensions for this lubrication oil tank are listed in table 6-4. Fig 6-4 Table 6-4 Lubrication oil tank main dimensions Booster lubricating oil tank Waterjet size Tank size Block dimensions Wet weight [ltr] L [mm] W [mm] H [mm] [kg] Installation notes for LOP The lubrication pump set needs to be installed in a position close to and below the suction line connection of the thrust bearing. To minimize line losses and avoid air locks, the lines connecting the pump set to the thrust bearing and the lube oil reservoir have to be of ample size and with the minimum number of bends. If possible lines have to be installed with a slope. Position the tank as close as possible to and above the thrust bearing block. In general maximum line length is 10m and maximum number of bends is Wärtsilä Waterjets Product Guide - a4-16 January 2017

35 Wärtsilä Waterjet Product Guide 6. Waterjet Component Selection 6.4 Shaft seal Seal selection As the selection of the seal is directly related to the selection of the thrust bearing, for preliminary design purposes it is possible to select the seal size from table 6-5 based on the jet size selected in section 5.2 or 5.3 above. Table 6-5 Seal selector and main data Seals: Mass, flushing details and block dimensions Jet size Seal size Mass (cps) 1 [kg] l [mm] d flange [mm] flush water [l/hr] o.o.r o.o.r Composite housing Installation notes for shaft seal The shaft seal is mounted on the inlet duct right behind the thrust bearing block and acts as a barrier to prevent water from entering the ship. The shaft seal requires two types of connections. One air connection to the inflatable seal and one connection to the flush water supply. The flush water requirements are stated in table 6-5. The flush water for the seal will disappear via the stern tube and the stator bowl to the environment. Maximum allowable flush water temperature at entry = 40ºC. For maximum seal life, the flush water should be filtered with a 200 [micron] mesh filter/strainer. Wärtsilä Waterjets Product Guide - a4-16 January

36 6. Waterjet Component Selection Wärtsilä Waterjet Product Guide The inflatable seal may be activated by air or a suitable liquid, with a maximum pressure of 5 bar. To deactivate the seal, the pressure should be decreased to atmosphere. 6.5 Hydraulic System Jet hydraulic systems Each steering and reversing waterjet requires one hydraulic power pack (HPP) for steering control and reversing actions. Two stainless steel hydraulic cylinders are used to pivot the jetavator to port and starboard and one central hydraulic cylinder to move the reversing plate up and down. Hydraulic cylinders are fitted with integrated position sensors linked to the electronic jet control system for feedback and indication. The hydraulic control for each steering and reversing waterjet installed is independent and failure in one hydraulic system will not affect the other jets installed Fig 6-5 Thrust directions Standard hydraulic power pack (HPP) The main hydraulic pump of the standard HPP is driven by a Power Take Off (PTO) from the gearbox or the prime mover. In addition to this, an electrically driven double pump is installed on the oil tank. One section of that pump (with a capacity of approx. 15% of the main PTO driven pump) can be used for moving the jet when the prime mover is not running and / or as a back-up in case of a failure to the main PTO driven hydraulic pump. The other section of the electrically driven pump (with a capacity of approx. 25% of the main PTO driven pump) is used for cooling and filtering of the oil. A standard power pack is equipped with: Electrically driven double pump with sections for start-up / back-up and cooling / filtering respectively Directional control valve to switch between start-up / back-up and normal operation Proportional valve for steering control complete with counter balance valves for load holding and overload protection Proportional valve for reversing control complete with counter balance valve for load holding and overload protection Possibility for manual operation of proportional valves 6-8 Wärtsilä Waterjets Product Guide - a4-16 January 2017

37 Wärtsilä Waterjet Product Guide 6. Waterjet Component Selection Seawater resistant heat exchanger mounted on tank Oil filter in return line with clogging indicator / electric signal and bypass Local pressure manometer for pump pressure indication Oil pressure switch on pressure side of the pump Oil level indicator Oil level switch Oil temperature switch Oil temperature indicator Fill, drain plug and silica breather Seperate section in tank for TBB lubrication oil Dimensions and general arrangement drawings Standard HPP s can serve every size waterjet in the range. The power pack required for your application will depend mainly on: The selected water jet size Desired steering and reversing response (settling times) The main (dimensional) data of the hydraulic power packs are printed on the pages following the hydraulic system selector. General arrangement drawings in.dxf/.dwg format can be submitted via on request or downloaded via a customer section on the Wärtsilä website. Please refer to chapter 11. Product Guide Attachments. The tables below make a preliminary power pack and PTO pump selection possible. The size of the PTO driven hydraulic pump will depend on all above mentioned parameters plus the speed (revolutions/minute) of the PTO on the gearbox or prime mover. Notes for the tables in the remainder of this chapter. 1 Standard settling time valid for the particular jet sizes. For example a settling time of 10/10 indicates steering from full board to board in maximum 10 seconds and reversing from full ahead to full astern in maximum 10 seconds. 2 Faster settling times are possible up to the minimum settling time indicated in table 6-6. Faster settling times will require larger and heavier pumps and sometimes larger and heavier power packs. 3 HPP size is related to jet size and design settling times 4 Please refer to figure 6-6 and tables for block dimensions, weight and connection details for a selected PTO pump and HPP size (separate tables for execution with 50Hz 380V IEC frame motor, table 6-8 and 60Hz 460V NEMA frame motor, table 6-9). 5 The main pump size will depend on the speed of the PTO on the gearbox or prime mover. If a high PTO speed is available, a smaller and lighter pump can be used. 6 The rpm for the PTO in table 6-6 describes the input speed for the pump at a maximum engine rpm. Wärtsilä Waterjets Product Guide - a4-16 January

38 6. Waterjet Component Selection Wärtsilä Waterjet Product Guide Table 6-6 Axial series water jets - PTO pump selector. Jet size Standard settling time stg/rev Pump for PTO 1000 rpm Pump for PTO 2000 rpm Minimum settling time stg/rev Pump for PTO 1000 rpm Pump for PTO 2000 rpm 510 6/6 b a 4/4 c a 570 6/6 c a 4/4 d b 640 6/6 c b 4/4 d c 720 7/7 d b 5/5 e c 810 8/8 d c 6/6 e c 910 8/8 g d 6/6 g e /8 g d 6/6 h e /9 g d 7/7 h e /9 h f 7/7 j g /10 j f 8/8 j g /10 j g 8/8 k h /11 j g 9/9 k h /14 j g 12/12 k h /14 k h 12/12 k h /16 k h 14/14 - j /20 - h 18/18 - h /22 - j 20/20 - j /24 - j 22/22 - j PTO pump data A range of variable displacement piston type PTO pumps are used. As a standard these pumps have a clockwise direction of rotation when looking to the pump shaft end (other direction of rotation can be supplied upon special request). The pump is selected based on the design requirements and the available nominal rpm of the PTO (see table 6-6 ) Wärtsilä Waterjets Product Guide - a4-16 January 2017

39 Wärtsilä Waterjet Product Guide 6. Waterjet Component Selection Fig 6-6 Typical PTO pump connection details In table 6-7 below the relevant connection and mass details for the range of standard PTO pumps are given. Table 6-7 PTO pump main data and connection details PTO pump size Max Dry weight Flange ISO 3019/2 Shaft execution splines DIN5480 Shaft length -mounting face L PCD D hole [rpm] [kg] [mm] [mm] [mm] [mm] a bolt 100 W25*1.5*15*8f b bolt 100 W25*1.5*15*8f c bolt 125 W32*1.5*20*8f d bolt 160 W40*1.5*25*8f e bolt 160 W40*1.5*25*8f f bolt 160 W40*1.5*25*8f g bolt 160 W50*2* 24*9g h bolt 160 W50*2* 24*9g j bolt 200 W60*2* 28*9g k bolt 250 W70*3* 22*8f Wärtsilä Waterjets Product Guide - a4-16 January

40 6. Waterjet Component Selection Wärtsilä Waterjet Product Guide Table 6-8 Axial series water jets - Hydraulic system data, HPP block dimensions, weights etc. with 50Hz 380V IEC frame aux motor Standard settling time Minimum settling time Jet size Block dimensions l - w - h Wet weight Required power Required cooling water flow Block dimensions l - w - h Wet weight Required power Required cooling water flow [mm] [kg] [kw] [l/min] [mm] [kg] [kw] [l/min] Table 6-9 Axial series water jets - Hydraulic system data, HPP block dimensions, weights etc. with 60Hz 460V NEMA frame aux motor Jet size Block dimensions l - w - h Standard settling time Wet weight Required power Required cooling water flow Block dimensions l - w - h Minimum settling time Wet weight Required power Required cooling water flow [mm] [kg] [kw] [l/min] [mm] [kg] [kw] [l/min] Wärtsilä Waterjets Product Guide - a4-16 January 2017

41 Wärtsilä Waterjet Product Guide 6. Waterjet Component Selection Jet size Block dimensions l - w - h Standard settling time Wet weight Required power Required cooling water flow Block dimensions l - w - h Minimum settling time Wet weight Required power Required cooling water flow [mm] [kg] [kw] [l/min] [mm] [kg] [kw] [l/min] Fig 6-7 HPP main dimensions Installation notes for HPP Long distances between the HPP and the waterjet and between the HPP and the PTO connection for the main hydraulic pump should be avoided. Pressure losses will occur in piping if connections are too far apart. This could reduce the performance efficiency of steering or reversing. Oil filled piping running through the vessel over long distances also increases installation weight and may cause Wärtsilä Waterjets Product Guide - a4-16 January

42 6. Waterjet Component Selection Wärtsilä Waterjet Product Guide problems with heat dissipation and noise transmission. If a large distance between PTO and waterjet cannot be avoided, we can, instead of using the PTO, supply full electrically driven power packs with the main pump directly mounted on or near the HPP tank. That way nearly all pressure and suction piping between PTO and HPP is saved. Please contact us for more information Wärtsilä Waterjets Product Guide - a4-16 January 2017

43 Wärtsilä Waterjet Product Guide 6. Waterjet Component Selection Fig 6-8 Schematic of standard power pack Wärtsilä Waterjets Product Guide - a4-16 January

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45 Wärtsilä Waterjet Product Guide 7. Design Considerations 7. Design Considerations Apart from the design criteria that are mentioned in the previous chapter, in the paragraphs "Installation notes", some overall design considerations apply. 7.1 Ship interfacing The waterjet installation interfaces with the ship in several locations. The ship s structure needs to be designed and machined correctly to allow proper installation and operation of the waterjet system Ship design considerations The bottom of the shaft must be at water level or below to enable the waterjet installation to prime. The minimum required height of the shaft centre line to bottom is presented in table 7-1 Waterjet dimension clearance for ship design. For the use of multiple waterjets, the sum of the side clearances can be taken to determine the minimum distance between two adjacent shaft centre lines. The side clearance per waterjet size is given in table 7-1. A smaller distance between shaft centre lines is possible, but in that case additional Anti collision provisions are needed. The inlet duct needs to be constructed to follow the ship s lines plan and the hydrodynamic profile as described in the custom made drawing from Wärtsilä. The inlet hydrodynamic profile is calculated using CFD software and taking the specific order data and requirements into consideration. Welds on the wetted side of the inlet duct need to be ground flush, to provide optimal performance. On request the inlet duct can be delivered by Wärtsilä as an option. At the output end of the inlet duct a flange is needed for mounting of the seat ring (impeller housing) and waterjet outboard part. This flange needs to be integrated in the transom. The (fluctuating) forces and moments generated by the waterjet act on the transom and need to be transferred from there into the vessel s structure. The position of the inlet duct and the flange are determined by the theoretical shaft centreline. The flange needs to be machined according to Wärtsilä drawing "Ship interfacing". Mounting of the seat ring, after the transom has been machined, determines the actual shaft line position. The transition between seat ring and inlet duct needs to be in line to prevent inadvertent disturbance of the water flow just upstream of the impeller. At the front of the inlet duct, the stern tube is constructed to allow the shaft to enter the ship. To prevent water from entering the ship, the shaft seal is mounted at the forward end of the stern tube. For proper mounting of the shaft seal the stern tube flange needs to be constructed and machined according to Wärtsilä drawing "Ship interfacing". For proper alignment of the shaft seal, the stern tube flange needs to be machined using the actual shaft line as reference. The thrust generated by the impeller will be transferred to the ship through the thrust bearing block. The thrust bearing block is also designed to support the shaft and needs to be aligned properly. To accommodate the position and thrust from the thrust bearing block, a foundation has to be made according to the project specific Wärtsilä drawing "Ship interfacing". A non conductive cast resin compound is used to fixate and electrically isolate the thrust bearing block from the ships structure. Necessary outboard connections (for a steerable reversible waterjet) are the hydraulic hose connections to the waterjet and the feedback wiring for steering and reversing positions. Optional outboard connections can be made for cooling water supply (from top of stator bowl) and cooling water outlet. Preferably these connections are made in the transom close to and Wärtsilä Waterjets Product Guide - a4-16 January

46 7. Design Considerations Wärtsilä Waterjet Product Guide above the waterjet. These connections must be made with a watertight throughput (except the cooling water outlet). Sacrificial anodes are mounted on the waterjet assembly to protect the unit and reduce the risk of corrosion to the hull/inlet duct in the vicinity of the waterjet. A proper cathodic protection system for the hull with due consideration of the presence of the stainless steel waterjet(s) has to be provided by the yard. It is highly recommended to add additional anodes on the transom near the waterjet and inside of the inlet duct. The entrained water given in table 7-1 is the estimated volume of water in the inlet duct (with a shape corresponding to the shaft height mentioned in the same table), causing extra weight in the ship. This should be taken into consideration during the design of the ship. Fig 7-1 Table 7-1 Waterjet dimension clearance Waterjet dimension clearance for ship design Waterjet size Side clearance [mm] Top clearance [mm] Entrained water [ltr] Shaft height [mm] Wärtsilä Waterjets Product Guide - a4-16 January 2017

47 Wärtsilä Waterjet Product Guide 7. Design Considerations Waterjet size Side clearance [mm] Top clearance [mm] Entrained water [ltr] Shaft height [mm] Wärtsilä Waterjets Product Guide - a4-16 January

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49 Wärtsilä Waterjet Product Guide 8. Propulsion Control System 8. Propulsion Control System The Wärtsilä Propulsion Control System is a complete user interface, which improves interactions and safety aboard ships of all sizes. Rather than a single product, it is a comprehensively designed system of levers and touch-screen interfaces, which takes into account and suits all possible propulsion configurations a modern ship can have. With the Wärtsilä Propulsion Control System the user is intuitively in control in all situations and in all conditions. The system s modularity makes installing, commissioning, configuration and maintenance simple and efficient, saving valuable time. 8.1 Propulsion Control System overview The propulsion control system consists of 2 major parts. At or near the machinery, the Propulsion Control Unit (PCU) is located. At the bridge a so called Bridge Control Unit (BCU) is present as well as individual control modules like levers and displays. The PCU communicates with the BCU via a redundant CAN OPEN field-bus. The PCU contains 2 redundant controllers which are connected to the machinery of the propulsion plant. Interfaces are present to gearbox clutch system, main engine and waterjet hydraulics and lubrication system. The BCU contains of 2 redundant communication controllers (gateways) which take care of all the internal data traffic between the connected bridge modules like levers and displays as well as with external systems like Auto Pilot, joystick, alarm and monitoring system and voyage data recorder Propulsion Control Unit Each propulsion control system will control one or more propulsor systems. In a configuration of four waterjets, one PCU will control the starboard waterjets and one PCU the port waterjets. The propulsion control unit is the central unit of the system and contains two controllers (PLC s) with I/O points: A main controller which handles all normal functionality like follow-up thrust control, engine start/stop, clutch control and mode selection. A back-up controller which is used for open loop control of thrust in case of malfunctioning of the main controller. An operator terminal is mounted in the cabinet door for local steering control as well as calibration and data presentation. The cabinet (IP44) is placed in the central/engine control room or inside the machinery space. The requirements for ambient conditions of this area are: Maximum ambient temperature: 55 C Minimum ambient temperature: 0 C Maximum relative humidity: 95% Wärtsilä Waterjets Product Guide - a4-16 January

50 8. Propulsion Control System Wärtsilä Waterjet Product Guide Fig 8-1 Control cabinet Remote control stations The minimal configuration for a remote control station is defined by a rotational lever, a side display and a steering indicator per waterjet. In a configuration of four water-jets in the vessel the minimal configuration for a remote control station is defined by 2 rotational levers, 4 side displays and 4 steering indicators. Optionally a main display can be delivered to accommodate common functions via a single user interface. Synchronous steering/thrust functions can be accommodated via separate double headed thrust levers and steering stick/steering wheel. The levers, displays and indicators are for indoor use and suitable for desk mounting. The modules must mechanically be fitted in a closed unit like a console or arm-rest. All connections of power supply and field-bus are via pre-fab cables between the modules and a so called distribution module. At each control station a distribution module for port as well as for s is present. 8-2 Wärtsilä Waterjets Product Guide - a4-16 January 2017

51 Wärtsilä Waterjet Product Guide 8. Propulsion Control System Fig 8-2 Example of a bridge panel Lever control unit The lever unit (IP22) is equipped stepper motors, an emergency stop button, a backup select button and an indication ring. The stepper motors are used during normal control for the synchronization of lever not in control and for electronic detents. During back-up control the same lever is used (without the stepper motor) with separate back-up electronics. The indication ring colour will indicate the applicable sailing mode of the water-jet. Manual (dark blue), Auto Pilot (light blue), back-up (yellow) or emergency stopped (red) and control transitions (orange flashing) Side displays The side display (IP22) is a 4.3 full color touchscreen and has its own electronics and is independent of the lever. The user interface supports functions for control transfer, mode selections, propulsor start/stop, engagement/disengagement of the clutch, indication of the controlled parameters, panel control functions like lamp test and dimming Control transfer between remote control stations Remote command control is present at one station at a time. Three procedures for control transfer between the remote control stations are defined: Take procedure: Used between stations at the same level (i.e. bridge level) which are visible from each other. Request / accept procedure: Used between stations at different levels or at the same level between stations which are not visible from each other. Forced transfer procedure: Used to transfer control unconditionally to a station which is defined as master station. The first two normal control transfer procedures (take and request / accept procedures) are always seamless. I.e. the thrust setting at the station where control is transferred to must be set in line with the thrust setting at the station in control at the start of the procedure before control can be transferred. Optionally control levers with electric shafts can be applied for automatic line-up. Wärtsilä Waterjets Product Guide - a4-16 January

52 8. Propulsion Control System Wärtsilä Waterjet Product Guide When in backup control all three normal control transfer procedures are disabled and backup control transfer between the different stations is active. Backup control transfer will be according the take procedure at all levels. 8.2 Control system layout The scope of supply for a waterjet control system varies with the layout of the waterjets. Most common waterjet layouts are ships with two or four steerable waterjets and ships with two steerable waterjets plus one or two booster waterjets. A configuration with three steerable waterjets is also possible but not common. Also a combination of a waterjet with two other propulsors (like a controllable pitch propeller) may occur as a non-standard lay out. A variation on a lay out with four steerable waterjets is a lay out where the waterjets are linked in pairs of two (see figure 4-10 Inboard hydraulic system); this is also a non-standard layout. 8-4 Wärtsilä Waterjets Product Guide - a4-16 January 2017

53 Wärtsilä Waterjet Product Guide 8. Propulsion Control System Basic four steering/reversing waterjet system Fig 8-3 Basic four steering/reversing waterjet system The above schematic layout is for a basic control system with four steering water-jets and 3 control positions at the bridge. The systems on port and s side are fully independent. Wärtsilä Waterjets Product Guide - a4-16 January

54 8. Propulsion Control System Wärtsilä Waterjet Product Guide Basic two steering/reversing waterjet system Fig 8-4 Basic two steering/reversing waterjet system This is a minor variation of the four waterjet system on the previous page. There are still two fully independent subsystems and thus two independent control cabinets mounted in the engine room as with the four waterjet system. 8-6 Wärtsilä Waterjets Product Guide - a4-16 January 2017

55 Wärtsilä Waterjet Product Guide 8. Propulsion Control System Basic two steering/reversing and booster waterjet system Fig 8-5 Basic two steering/reversing and booster waterjet system This is a minor variation of the two waterjet system on the previous page. The centre booster jet doesn t generate steering or reversing signals and is added to either the port or starboard system. In case of two boosters one is added to each independent side. 8.3 Functional description Basic system description The Wärtsilä propulsion control system is designed to control the steering angles, reverse bucket positions and the speed setting (rpm) of the installed waterjets. Clutch control as well Wärtsilä Waterjets Product Guide - a4-16 January

56 8. Propulsion Control System Wärtsilä Waterjet Product Guide as interfaces for remote start/stop of the engine can be integrated within the waterjet control system. Low level third party engine/gearbox monitoring, control and safety functions are not part of the propulsion control system and must be supplied as by the third party manufacturers Basic main control features The principal main features of Wärtsilä remote control system are: Remote control from the centre bridge and optional control stations like bridge wings if installed. Individual steering and thrust (bucket and rpm) control for each steering waterjet by means of steering / power control heads. Synchronous steering and thrust control for all waterjets by means of the steering/power lever of one steering/power control head. Optional synchronous steering control for all waterjets by means of a steering stick (arm rest) or steering wheel while individual thrust can be controlled using a double headed power lever. Indication of steering angles, bucket positions and rpm's. Clutch control and monitoring for each waterjet (if applicable). Automatic thrust-bearing lubrication control for all waterjets Extended main control features The basic control systems as displayed on the previous pages can be extended with additional features. The main extended feature is a vessel coordinating control system for LIPS-STICK (joystick) control interfacing with the individual waterjet control systems and the navigation equipment like GPS, VDR, AMCS. The navigation equipment itself as a standard is not included in our supply. 8-8 Wärtsilä Waterjets Product Guide - a4-16 January 2017

57 Wärtsilä Waterjet Product Guide 8. Propulsion Control System Fig 8-6 Two waterjet system with vessel coordinating control system for LIPS-STICK (joystick) control In case the vessel is equipped with a bow-thruster, the bow-thruster control is integrated in the coordinating control system. The coordinating control system will be integrated into 1 of the BCU cabinets. A second main feature that can be added to the basic systems as displayed on the previous pages is autopilot control on the main bridge station. Wärtsilä Waterjets Product Guide - a4-16 January

58 8. Propulsion Control System Wärtsilä Waterjet Product Guide Control modes Depending on the mission profile of the vessel and the applied machinery concept, different operating modes may be included in the control system or are made available on customer request. With each mode a different setting of steering and reversing is applied as function of the control lever position. The settings are based upon pre-calculated combinatory curves. Typical operation modes: Transit mode: In transit mode the steering and thrust of all waterjets are set synchronous. The steering angles set by the steering joystick are automatically limited as function of the craft speed. The steering angles of port waterjet(s) and starboard waterjet(s) can be scheduled independent to set different steering angles for waterjet(s) at the inward and outward side of the vessels turning circle. Manoeuvring mode(s): Within manoeuvring mode the steering and thrust of the waterjets are set individually by means of the rotating steering/power lever units. The thrust set by the levers is separated in a bucket and rpm demand which are sequentially controlled. Coordinated control mode(s) (LIPS-STICK mode, optional): In LIPS-STICK mode the steering and thrust of all waterjets are controlled simultaneously such that the requested surge, sway and yaw motions are followed by the vessel. Moving the two-axis joystick in ahead or astern direction sets the surge motion of the vessel. The transverse direction sets the sway motion. The vessels yaw motion can be set by rotating the spring centred moment knob. Surge, sway and yaw motions can be set individually or simultaneously. Manoeuvre impeller rpm can be set as additional variable. Auto-pilot mode (optional with auto-pilot delivery): In auto-pilot mode all waterjets are steered such that the set course is followed by the vessel automatically. Autopilot mode affects only the steering control and not the waterjet thrust control. Auto Pilot mode can be selected or made available at the side or main display Back-up control (non follow-up control) Indication In case the Follow Up (FU) system fails, Non Follow Up (NFU) back-up control can be selected by means of a push-button present at the lever. In back-up the steering and reversing is controlled via the same lever without the use of the electric stepper motors and via separate electronics. In case of a FU control system failure, an alarm is given and the operator is advised to select back-up control by a flashing indication at side display/main display (if present) and at the lever back-up push-button. Indication of steering/bucket and impeller rpm is present at the side display. For common use these parameters are also indicated at separate overhead indicators. Loose indicator boxes are an option. In general to comply to class rules for bridge steering indication the steering indicator system is independent from the remote controls Anti collision (optional) In multiple steering waterjet systems the risk of collision can exist if the distances between the waterjets in the hull are too small for unlimited movement of the jetavators. In that case both the follow up and non follow up system has to be extended with an anti-collision algorithm. This algorithm continuously checks the distance between waterjets and blocks (or decreases) the steering control of the waterjet that approaches the other Cavitation control (optional) The allowable impeller rpm is dependent on the actual ship speed. If the impeller rpm exceeds the allowable rpm, cavitation will occur at the impeller. This will cause damage to the impeller, 8-10 Wärtsilä Waterjets Product Guide - a4-16 January 2017

59 Wärtsilä Waterjet Product Guide 8. Propulsion Control System reducing its performance and lifetime. To prevent this, cavitation control can be added to the controls. If during design we notice that the cavitation margin is relatively small, Wärtsilä can include the cavitation control to ensure the waterjet unit will reach an acceptable lifetime Clutch control The remote control system will take care of remote clutch engagement/disengagement and interlocks of these clutches. The clutch(es) can be operated via the side display at the main control station. In case of a too low clutch pressure, an auto-declutch is performed and an alarm is given Prime mover control The propulsion control system can interface with the prime mover(s) driving the propulsor. The system will handle remote start/stop and the rpm settings. For emergency situations a main engine emergency stop push button is present at all the levers. A start allowance signal is going to the engine to prevent local starting when not allowed (e.g. the clutch must be disengaged) Slow down request If status conditions of prime mover, gearbox, thrust bearing block and/or hydraulic system require, the ship s alarm and monitoring system will generate a SLOWDOWN REQUEST to the propulsion control system to reduce the load. At a slow-down the load controller will reduce the waterjet rpm to a predefined setting (this is an adjustable value inside the control system). The operator has the possibility to manually override the slowdown from the remote control stations Pump control Alarming The propulsion control system is able to remotely start and stop electrically driven lubricationand hydraulic pumps. In case a main hydraulic PTO-pump is present, an accompanying electrically driven pump on the hydraulic power pack is used for start-up and shutdown of the system. At start-up this pump is started from the remote control station and will stay on until the system is shut-down. This is done so the electrically driven double pump will continuously pump the oil through the oil cooler. In case of a failure in the propulsion control system, an alarm is generated and given to the alarm system. Essential alarm signals from the remote control system to the alarm system are hardwired potential free and normally closed contacts where as a MODBUS serial connection provides all other alarms. 8.4 Interfaces to non propulsion machinery (external systems) Voyage Data Recorder (VDR) From the normal control system a serial RS-422 data interface is available. The information for the VDR is sent in a propriety string according to the NMEA-0183 standard. The data string will contain information like which station is in control, (major) alarm active and the actual status and feedback signals of steering, bucket and rpm. Wärtsilä Waterjets Product Guide - a4-16 January

60 8. Propulsion Control System Wärtsilä Waterjet Product Guide Joystick System (JS) The propulsion control system can interface with an (external) joystick system. The JS demands will be followed as soon as a JS REQUEST signal is received. An acknowledge signal to the JS system is available to indicate that the JS system is in control. The control system will give a READY FOR JS signal when the system has no failure and is prepared for JS control. The physical interface for the external JS systems is at the BCU cabinet (bridge). Override of the joystick mode is available for each individual propulsor (jet) at the side or main display Integrated Automation System (IAS) The propulsion control system can interface with an Integrated Automation System. System status information like alarms, orders and (sensor) feedbacks can be made available. MODBUS protocol is available for interfacing to the IAS. 8.5 Installation Electrical installation Electrical connections between cabinets, control stations, prime mover, reduction gear, alarm and monitoring system and other systems will be indicated on project specific drawings (Cable and Connection diagrams). External binary, analogue or serial connections to and from other ship equipment must be galvanically isolated from the remote control system. The signal supplier needs to isolate the signal. Contacts are to be potential free and suitable for 500mA maximum at 24V DC. Analogue signals are typical 4-20mA or +/-10V. Signal cables must not be installed and routed together with (high) power cables. Minimum distance between signal and power cables is 0.3 meters when running in parallel over more than two meters. The propulsion control system must be earthed in accordance with classification society requirements. Cables connecting the different remote control system components and other equipment are customer delivery. Also cable glands for the propulsion control unit are not supplied by Wärtsilä. Table 8-1 Cable types Signal Digital Analogue Serial Drive Power Signal type On/Off (24V DC) signals 4-20 ma signals +/-10V signals (potentiometer) RS-422 (NMEA, fieldbus) Valve driver signals 120/230V 500V, 50/60Hz AC24V DC Cable type 0.75 mm² overall screened 0.75 mm² screened pair 0.75 mm² screened pair 1.5 mm² overall screened Depends on type of power supply and length of cables, customer to determine Power supply The propulsion control system requires two separate power supplies to each control cabinet. A main power and a backup source connection are foreseen. At the bridge control stations so called power distribution units are present which needs 2 independent power sources as well. In case of a power failure of the main supply, the system switches over to the back-up supply without interruptions and an alarm is given. The backup power source must according to 8-12 Wärtsilä Waterjets Product Guide - a4-16 January 2017

61 Wärtsilä Waterjet Product Guide 8. Propulsion Control System classification rules be executed as a battery back-up or UPS. The propulsion control system is designed to internally work with 24V DC. The propulsion control unit is able to receive (and convert) current from 120/230V 500V, 50/60Hz AC (single phase) and 24V DC power sources. Optionally a separate power cabinet can be supplied with or without battery backup, for transformation of off-standard power sources to 24V DC Mechanical installation Remote control modules and cabinets must be installed according the project specific installation drawings. The remote control modules (e.g. levers, displays) are suitable for desk mounting. The control cabinets should be placed in a suitable location where the requirements for ambient conditions like temperature, vibration and humidity are met. A reference is made in section Propulsion Control Unit. Wärtsilä Waterjets Product Guide - a4-16 January

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63 Wärtsilä Waterjet Product Guide 9. Main Data 9. Main Data 9.1 Waterjet dimensions and weights Fig 9-1 Table 9-1 Waterjet dimensions Waterjet weight and dimensions Jet size Inboard length 1 Transom flange Outboard length (SR) Weight (SR) Outboard length (B) Weight (B) [mm] [mm] [mm] [kg] [mm] [kg] Inboard length may vary depending on the optimized shape of the inlet duct. Wärtsilä Waterjets Product Guide - a4-16 January

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65 Wärtsilä Waterjet Product Guide 10. Drawings 10. Drawings 10.1 List of Drawings DAAK Interface drawing reverse jet... DBAC Waterjet selection questionnaire Wärtsilä Waterjets Product Guide - a4-16 January

66 10. Drawings DAAK Interface drawing reverse jet Wärtsilä Waterjet Product Guide 10-2 Wärtsilä Waterjets Product Guide - a4-16 January 2017

67 Wärtsilä Waterjet Product Guide 10. Drawings DBAC Waterjet selection questionnaire Document title: WATERJET selection questionnaire Doc. no. Rev. Date Template no. DBAC993354/- Page 1 of 2 Company Details Company Address Telephone Fax Contact person General Data Order number Yard New building number(s) Owner QMS-Number Project Reference Number of Vessel(s) Operating Profile PROJECT REFERENCE TYPE OF CRAFT APPLICATION HULL MATERIAL Monohull Catamaran SES Other:. Ferry Navy Yacht Other:. Aluminium Steel GRP Other:. Wärtsilä Waterjets Product Guide - a4-16 January

68 10. Drawings DBAC Waterjet selection questionnaire Wärtsilä Waterjet Product Guide Document title: WATERJET selection questionnaire Doc. no. Rev. Date Template no. DBAC993354/- Page 2 of 2 CRAFT DATA L.O.A. (m) TRIAL DISPL. (t) L.W.L. (m) FULL DISPL. (t) BEAM (m) DEADRISE ( ) DRAFT (m) LCG from transom (m) PROPULSION CONFIGURATION ENGINE TYPE ENGINE TYPE No. OF ENGINES No. OF ENGINES MAX POWER (kw) MAX POWER (kw) MAX RPM* MAX RPM* CONT POWER (kw) CONT POWER (kw) CONT RPM* CONT RPM* No. OF WATERJETS No. OF WATERJETS INLET DUCT TO BE SUPPLIED (YES**/NO) *please supply RPM when no reduction gearbox is to be applied **only applicable for Plug and Play Midsize Waterjet, types 510, 570, 640, 720, 810 PERFORMANCE DESIGN SPEED (kts) CONT. SPEED (kts) MAX. SPEED (kts) OTHER (kts) THRUST PREDICTION (@ load)** SPEED (kts) THRUST (kn) **if possible please supply datasheet (Excel) with thrust prediction WATERJET CONTROLS No. OF CONTROL STATIONS CLASSIFICATION CLASSIFICATION NOTATION DELIVERY TIME REQUIRED DELIVERY TIME (MM/YYYY) SPECIAL REQUIREMENTS CLASS Cells are necessary for a proper Waterjet Selection 10-4 Wärtsilä Waterjets Product Guide - a4-16 January 2017

69 Wärtsilä Waterjet Product Guide 11. Product Guide Attachments 11. Product Guide Attachments This and other product guides can be accessed on the internet, from the Business Online Portal at Product guides are available both in web and PDF format. Drawings are available in PDF and DXF format, and in near future also as 3D models. Consult your sales contact at Wärtsilä to get more information about the product guides on the Business Online Portal. Wärtsilä Netherlands B.V. T: +31 (0) P.O. Box BB, Drunen The Netherlands waterjets@wartsila.com Scan this QR-code using the QR-reader application of your smartphone to obtain more information. Wärtsilä Waterjets Product Guide - a4-16 January

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71 Wärtsilä Waterjet Product Guide 12. Annex 12. Annex 12.1 Unit conversion tables The tables below will help you to convert units used in this product guide to other units. Where the conversion factor is not accurate a suitable number of decimals have been used. Table 12-1 Length conversion factors Table 12-2 Mass conversion factors Convert from To Multiply by Convert from To Multiply by mm in kg lb mm ft kg oz Table 12-3 Pressure conversion factors Table 12-4 Volume conversion factors Convert from To Multiply by Convert from To Multiply by kpa psi (lbf/in 2 ) m 3 in kpa lbf/ft m 3 ft kpa inch H 2 O m 3 Imperial gallon kpa foot H 2 O m 3 US gallon kpa mm H 2 O m 3 l (litre) 1000 kpa bar 0.01 Table 12-5 Power conversion factors Table 12-6 Moment of inertia and torque conversion factors Convert from kw kw To hp (metric) US hp Multiply by Convert from kgm 2 knm To lbft 2 lbf ft Multiply by Table 12-7 Fuel consumption conversion factors Table 12-8 Flow conversion factors Convert from To Multiply by Convert from To Multiply by g/kwh g/hph m 3 /h (liquid) US gallon/min g/kwh lb/hph m 3 /h (gas) ft 3 /min Wärtsilä Waterjets Product Guide - a4-16 January

72 12. Annex Wärtsilä Waterjet Product Guide Table 12-9 Temperature conversion factors Table Density conversion factors Convert from To Calculate Convert from To Multiply by C F F = 9/5 *C + 32 kg/m 3 lb/us gallon C K K = C kg/m 3 lb/imperial gallon kg/m 3 lb/ft Prefix Table The most common prefix multipliers Name tera giga mega kilo milli micro nano Symbol T G M k m μ n Factor Wärtsilä Waterjets Product Guide - a4-16 January 2017

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76 Wärtsilä is a global leader in complete lifecycle power solutions for the marine and energy markets. By emphasising technological innovation performance of the vessels and power plants of its customers. Wärtsilä is listed on the NASDAQ OMX Helsinki, Finland. WÄRTSILÄ is a registered trademark. Copyright 2017 Wärtsilä Corporation.