Reference project Automation of a
ship propulsion system
A secure foundation for climate-friendly drives in shipping
Shipping faces numerous challenges. It is one of the biggest sources of emissions worldwide. New limits for the sulphur content of fuels have been in force since the beginning of 2020. An important contribution to improving the global climate is therefore to avoid using heavy fuel oils and instead use low-emission fuels such as liquid gas or hydrogen. This applies in particular to voyages close to the coast or during port layovers. Those who operate such systems in an optimized manner and monitor them consistently in future will enjoy a decisive competitive advantage. A variety of process engineering systems have already been developed and implemented, especially for new ships. The major challenges of the future lie on the one hand in the standardization of such systems and in the creation of concepts for retrofitting or converting ships already in operation. On the other hand, ships equipped with such modern propulsion systems must also be supplied with fuel via bunker ships or on land via LNG terminals. In both cases, the gas is stored deep-frozen in vacuum-insulated tanks. Due to the increased risk potential, the refueling process requires more effort in the design, automation and monitoring of the systems. In addition, special measuring and safety equipment is required to ensure trouble-free and safe operation.
Project details
- Automation of an innovative dual-fuel drive concept
- Highest safety requirements of various authorities
- Coupling to process engineering simulation system
SpiraTec AG was commissioned to plan and implement the automation of a high-pressure dual-fuel system. A large number of national and international regulations and rules had to be complied with. The precise knowledge of these and the creation of new technical regulations in cooperation with the various classification societies were key challenges and decisive for the successful realization of the project. The inclusion of the US Coast Guard regulations and the UL (Underwriters Laboratories) building regulations were of particular importance.
PCS 7 (redundant and fail-safe) with intrinsically safe I/O
Design and switch cabinet construction according to UL
Verification calculations for SIL and EX protection
FAT with DNV and US Coast Guard on simulated system
Gas trail and commissioning with the participation of the classes and teams
First virtual, then real
Even before the entire system was installed on the ship, a process simulation was carried out for specific parts of the process engineering system. This allowed important functions to be put into virtual operation. This not only provided security during the actual commissioning, it also significantly reduced the usual time and costs.
“By shifting dangerous processes from humans to technology, we avoid risks and other sources of error.“
Production manager on the customer side
Comfortable monitoring
In the future, the monitoring of such complex systems will become even more important. By consistently recording and storing data during operation, conclusions can be drawn about emission avoidance and cost reduction. Data storage in cloud systems enables controlled access from land and is an important prerequisite for safe operation. In addition, this data forms a fundamental basis for predictive maintenance. The system recognizes in advance when warning limits are reached and special services are required. This is an important contribution to safe operation, the creation of remote diagnoses and the avoidance of unnecessary deployment of service personnel worldwide.