18 Dicembre 2013 La progettazione di una grande nave da crociera

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1 18 Dicembre 2013 La progettazione di una grande nave da crociera Alessandro Maccari

2 Organizzazione aziendale e project management Aspetti generali di progettazione di base di una grande nave Strumenti per la progettazione idrodinamica - simulazioni CFD, ottimizzazione carena ed eliche Progettazione strutturale - analisi statica e dinamica, globale e locale Rumore irradiato in acqua ed in aria Impianti di generazione diesel-elettrica e propulsione aspetti di energy saving e contenimento delle emissioni inquinanti Production Engineering e logistica di produzione

3 FINCANTIERI at a glance 5 th most important shipbuilding group in the world 21 shipyards in 3 continents About employees (8400 in Italy) 1 st player in terms of diversification & activities in high-value sectors: UNIQUE OPPORTUNITIES OF CROSS-FERTILIZATION 65 cruise ships built 1/3 of worldwide fleet carrying 8M pass./year

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5 200 YEARS OF TRADITION, 7000 SHIPS BUILT

6 Life-Cycle Management PROJECT MANAGEMENT Proposal / Initial Design MOA Basic Design and Negotiation C O N T R A C T Design Documents Completation Operative Planning Functional Design Coordination Design Executive Design and subdivision in Pallets Executive Planning and work scheduling S K L D Production from raw material Pre-fitting and pre-assembly of blocks Keel laying, assembling and launching Sea Trials Delivery Outfitting Commisioning Material provision and expediting Precontractual Phase Start Development Production Delivery Approx. 12 months Approx. 24 months

7 Organizzazione aziendale e project management Aspetti generali di progettazione di base di una grande nave Strumenti per la progettazione idrodinamica - simulazioni CFD, ottimizzazione carena ed eliche Progettazione strutturale - analisi statica e dinamica, globale e locale Rumore irradiato in acqua ed in aria Impianti di generazione diesel-elettrica e propulsione aspetti di energy saving e contenimento delle emissioni inquinanti Production Engineering e logistica di produzione

8 Ship design is a complex process involving the integration of many subsystems into a final solution which must simultaneously meet cost and effectiveness measures

9 The role of a shipyard Coordination of different stakeholders Integration of solutions, systems, components Careful planning of make-buy strategies Cost-effectiveness & Value for money Product & Process optimization (design & production)

10 Basic Design Dept. Main Activities General Arrangement plan Ship Technical specification Ship Weight breakdown Capacity plan Bulkhead plan Loading Conditions Geometric Midship Section Engine room Arrangement and in principle Diagrams G020 * DECK 4 Preliminary balances (electrical, air, water, steam) Plants / Architects border definition Precoordination plans Cabin layouts Catering item list and layouts HVAC / Ventilation calculations G020 * CUCINE-RIPOST.-BANCHI BAR-PREPAR. ROOM G020 * DECK 3 G * Deck 3 - Crew galley oss G Pavimentazione CR-ARR PRC-01 mq ,00-7,00 8,62 G Coaming, foundation and gutterway CR-ARR PRC-01 mq ,00-7,00 8,65 G Pareti CR-ARR PRC-01 mq 85 35, ,00-7,00 9,80 G Porte CR-ARR PRC-01 n ,00-7,00 9,55 G Soffittature CR-ARR PRC-01 mq 85 17, ,00-7,00 11,05 G Imp. Elettrico CR-ARR PRC-01 mq ,00-7,00 9,95 G Imp. Idrico CR-ARR PRC-01 mq ,00-7,00 conteggiati gli allacciamenti, il peso dei tubi delle sottostazioni è conteggiato 9,05 nella WBS D_fam G Arredamenti CR-ARR PRC-01 mq ,00-7,00 9,55 G G * Totale area ,00-7,00 9,52 G * TOTALE DECK ,00-7,00 9,52 G * Deck 4 - Galley oss G Pavimentazione CR-ARR PRC-01 mq ,00 0,00 11,52 G Coaming, foundation and gutterway CR-ARR PRC-01 mq ,00 0,00 11,55 G Pareti CR-ARR PRC-01 mq , ,00 0,00 12,70 G Porte CR-ARR PRC-01 n ,00 0,00 12,45 G Soffittature CR-ARR PRC-01 mq , ,00 0,00 13,95 G Imp. Elettrico CR-ARR PRC-01 mq ,00 0,00 12,85 G Imp. Idrico CR-ARR PRC-01 mq ,00 conteggiati gli allacciamenti, il peso dei tubi delle sottostazioni è conteggiato 0,00 11,95 nella WBS D_fam G Arredamenti CR-ARR PRC-01 mq ,00 0,00 12,45 G G * Totale area ,00 0,00 12,42 G * TOTALE DECK ,00 0,00 12,42

11 This system cannot possibly go wrong But if it goes wrong, it turns out to be impossible to get at, or repair Maybe we should have done those backups...

12 Back to 1994 The vessel should be designed against performance criteria, on the basis of the application of assurance technology techniques, to ensure that the vessel is safe, reliable, easily maintained and has high availability Owner s targets for business, environmental & safety performance of the ship These issues had never before been addressed in this way for a cruise ship THE RESULT 120 cm / 47 in. Inaugural Cruise: May 26, 1998 Tonnage: 107,517 Passenger Cabins: 1,301 Length: 949 feet Height: 188 feet 17 Decks Registry: Bermuda

13 present past EVOLUTION OF RELIABILITY, AVAILABILITY, REDUNDANCY Additional Class Notations Availability of Machinery Duplicated Propulsion System Independent Propulsion System SOLAS Safe Return to Port design criteria - not details Selected scenario Casualty threshold (fire / flooding) One of the first ever to build a fully certified SRTP large cruise ship Today: innovative arrangements, layouts and design configurations Pragmatic trade off : complexity vs. reliability & availability

14 Organizzazione aziendale e project management Aspetti generali di progettazione di base di una grande nave Strumenti per la progettazione idrodinamica - simulazioni CFD, ottimizzazione carena ed eliche Progettazione strutturale - analisi statica e dinamica, globale e locale Rumore irradiato in acqua ed in aria Impianti di generazione diesel-elettrica e propulsione aspetti di energy saving e contenimento delle emissioni inquinanti Production Engineering e logistica di produzione

15 Naval Architecture ACTIVITIES COVER THE ENTIRE SHIP LIFE-CYCLE PRECONTRACTUAL Main hydrodynamic characteristics (propulsion, manoeuvring, etc.) Preliminary hull forms Basic stability requirements DESIGN DEVELOPMENT Hull forms, appendages, propeller Hydrodynamic calculations, model tests Stability calculations Capacity plan DELIVERY Sea trials, Inclining test Final delivery documents approved by Class & National Flag Authority

16 ACTIVITIES DESCRIPTION HULL FORM DESIGN Optimised by Computational Fluid Dynamic (CFD - potential and viscous flow codes) - and model tests Model basins: MARIN, SSPA, VMB, Krylov, DMI Hull form developed using NAPA system, for subsequent use in stability calculations and steel structure design APPENDAGES DESIGN Shaft brackets, rudders, pod, bilge keels Optimum position and orientation carried out by viscous flow CFD and model tests. Target: minimum resistance, optimum water inflow to the propeller, minimisation of cavitation phenomena, maximum comfort

17 PROPELLER DESIGN Fixed pitch propeller design & verification Strict co-operation with controllable pitch propellers suppliers throughout the design process Tools: traditional lifting surface theory, newly developed panel method code, model tests evaluation of propulsive performance, cavitation, induced hull pressure pulses, integrated forces for 3D vibration analysis. Blade design to minimise in-water energy generated by the propeller (blade frequency pressure pulses, broad-band energy) in relation to noise and vibration limits. Model tests in advanced facilities, analysed on a wide frequency range Application of CFD, based on viscous flow (RANSE codes), to decrease excitation forces and noise generated by the propeller.

18 MANOEUVRING AND CRABBING Calculations using a code based on statistical hydrodynamic coefficients Model tests in an ocean basin (MARIN, SSPA, MARINTEK) Evaluation of manoeuvring performances Evaluation of transverse thrusters arrangement & power to meet the required crabbing criteria SEAKEEPING Calculations with linear code (motions, accelerations, etc.) Operational study based on longt term analysis tailored on ship mission profile Model tests in an ocean basin (MARIN, SSPA, MARINTEK, Krylov)

19 STABILITY Intact and Damage stability calculations, using NAPA system Approval process with Flag Authorities & Classification Societies LOADING CONDITIONS Stability, trim, bending moments and shear forces Continuous check of deadweight and stability margins compared with the scheduled lightweight throughout the design process SEA TRIALS Check proper loading condition to reach the required draught and trim Carry out speed and manoeuvring preliminary and official trials INCLINING TEST Preparation of the official inclining test (loading condition and procedure) Performing the test, measurement of all necessary data Stability manual based on final lightweight data and submission to Class for approval

20 Naval Architecture activities Free surface simulation (viscous code)

21 Naval Architecture activities -Shaft and Struts orientation -Wake analysis (Viscous Computation)

22 Naval Architecture activities Appendages Design

23 Naval Architecture activities

24 Naval Architecture activities

25 Naval Architecture activities

26 Naval Architecture activities Hull and superstructure design

27 Organizzazione aziendale e project management Aspetti generali di progettazione di base di una grande nave Strumenti per la progettazione idrodinamica - simulazioni CFD, ottimizzazione carena ed eliche Progettazione strutturale - analisi statica e dinamica, globale e locale Rumore irradiato in acqua ed in aria Impianti di generazione diesel-elettrica e propulsione aspetti di energy saving e contenimento delle emissioni inquinanti Production Engineering e logistica di produzione

28 PRECONTRACTUAL Structural Configuration for G.A. Plan; Midship Section: Main Scantlings, preliminary assessment of Longit. Strength (DNV NAUTICUS, LR Rules) Hull Weight and Center of Gravity; Technical Specification for Hull and Painting CONTRACTUAL Detailed Midship Section Hull Modelization (NAPA Steel ) Horizontal, Longitudinal, Transversal Sections for Class and Owner approval (NAPA Steel / MICROSTATION) Rule Scantlings and Structural Static Analyses for Longitudinal / Transversal / Local Fatigue / Buckling strength by F.E. Models (PATRAN / NASTRAN) Qualitative Dynamic Analyses (PATRAN / NASTRAN) Design of Passenger Crew Stairs Painting Specification and related documents Hull Activities

29 Hull Activities STRUCTURAL DESIGN from Macro to Micro (PATRAN/NASTRAN) Longitudinal Strength (Still water/ Wave/ Whipping) Global F.E. Models Transversal Strength (Racking) Global F.E. Models Local Strength: Local Areas of Overhanging/Critical Openings in Longitudinal/Transversal Bulkheads/Main Lounges/ Atrium/ Funnel/ Mast Static and Dynamic, Local Stress Concentration, Buckling, Fatigue Local F.E. Models

30 Hull Tools NAPA STEEL

31 Global finite elements models

32 Disco of Grand Princess Class

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34 Analysis of stress concentration

35 Hull Activity

36 Pod of Vista Class

37 Transverse deflection of superstructure

38 Hull Tools Local Strength (door frame model): NASTRAN PATRAN

39 Noise and Vibration Activities

40 Noise and Vibration Activities

41 Noise and Vibration Activities Max Vibration Velocity

42 Mode 1 Torsion Noise and Vibration Activities Mode 3

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44 Organizzazione aziendale e project management Aspetti generali di progettazione di base di una grande nave Strumenti per la progettazione idrodinamica - simulazioni CFD, ottimizzazione carena ed eliche Progettazione strutturale - analisi statica e dinamica, globale e locale Rumore irradiato in acqua ed in aria Impianti di generazione diesel-elettrica e propulsione aspetti di energy saving e contenimento delle emissioni inquinanti Production Engineering e logistica di produzione

45 Underwater Noise Emissions

46 ISO Protecting marine ecosystem from underwater radiated noise Measurement and reporting of underwater sound radiated from merchant ships Standardization in the field of under water acoustics IMO Provision for the reduction of noise from commercial shipping and its adverse impacts on marine life EC Several research projects & specialist groups Standard and Regulations do not specify or provide any criteria for adverse effect of underwater sound radiated from ships to marine ecosystem. 6

47 overlapping groups and initiatives lack of coordination and clear objectives who is doing what? what are we looking for? impact on ship design - production operation? Industry noise WG 7

48 Yard Efforts Calculation model based on SEA (Statistical Energy Analysis): 1. Covering a large range of frequencies; 2. Showing how energy generated by sources on board (vibrations and/or sound waves) spread through the structure into the sea; 3. Building a large data base of materials and structural response

49 MACHINERY ROOM AIRBORNE NOISE IRRADIATED INTO THE WATER

50 MACHINERY ROOM STRUCTURAL NOISE IRRADIATED INTO THE WATER

51 Underwater Noise Limits and Measurement Procedures 11

52 Human hearing Human beings can hear frequencies from about 20Hz to 20kHz

53 Biologists TTS temporary threshold shift PTS permanent threshold shift Experiments to measure PTS in marine mammals are unethical Consequently, researchers have concentrated the study on TTS The sound pressure levels at which PTS are expected to occur are estimated using the experience on human beings of the sound level differences between TTS & PTS

54 ISO Methodology L 2L 2L d 3 D A CPA C D B d 7 1 target ship 3 2 Sailing course 3 Observation vessel or buoy 4 hydrophone A Measurement start point B Measurement end point C Position of the hydrophone D Horizontal distance between the target ship and hydrophone L Overall length of the target ship

55 CETENA Methodology The in-water unit is deployed using a lifeboat The buoy is fastened to the lifeboat by a floating rope.

56 Acoustic Signature Database for Cruise Vessels 16

57 ambiguous response because there are no unique and agreed criteria

58 Underwater Noise Emission Sources Underwater sound transmission Noise sources with respect to underwater noise emission

59 Calculations Finite Element models (software Actran + ANSYS) built up for machinery and propeller noise sources Hull vibration Propeller noise

60 Calculations 20*Log(r/r0), i.e. 6 db 20

61 Calculations Propeller Source Sheet cavitation Broad Band Transfer function 150 mm spacing 100 mm from the hull 21

62 Calculations Summary Objective: Automatic system on board to evaluate actual noise emissions lower emission strategies (e.g. changing speed)

63 Organizzazione aziendale e project management Aspetti generali di progettazione di base di una grande nave Strumenti per la progettazione idrodinamica - simulazioni CFD, ottimizzazione carena ed eliche Progettazione strutturale - analisi statica e dinamica, globale e locale Rumore irradiato in acqua ed in aria Impianti di generazione diesel-elettrica e propulsione aspetti di energy saving e contenimento delle emissioni inquinanti Production Engineering e logistica di produzione

64 REDUCED FUEL USAGE FUEL COST SAVING MARPOL Annex VI (Jan.2013) Energy Efficiency EEDI mandatory for new ships, SEEMP for all ships Rising cost of fuel is the real driver behind marine clean technology adoption Focus on solutions by pay back timescale Return of 3-5 years required on environmental tech. investment

65 Why emphasis on Life-Cycle Cost? Shipbuilders live merrily until they meet the accountant

66 Net Present Value calculation NPV costs of a product over its entire life-cycle Initial investment costs + running costs and revenues The life-cycle can be subdivided into different phases, as necessary e.g. addition of new cabins, energy-saving retrofitting Pay-Back-Time

67 For the past several years cruise lines and yards looking for more energy efficiency Price targets for cruise ships getting more and more challenging Ships getting more and more complex Improved guests expectations, enhanced safety standards Strict environmental requirements. Are we reaching the end of the road? Can we streamline any more and cut costs? How?

68 Energy saving as a key design driver FINCANTIERI: More than 90 energy-saving interventions implemented on new ships: Hydrodynamic & Propulsion Efficiency Energy Generation & Distribution Accurate & Dynamic power management Air Conditioning & Ventilation Heat Recovery Electrical Control Systems & Automation

69 Energy saving = propulsion or more??? maximum speed, ambient temperature, house lighting, ventilation, galley equipment, local entertainment, thermal insulation, k-factor of glazing, solar cells, pods, new materials, air conditioning, hull forms, antifouling, propellers, fixed/variable speed equipment, led lights, fan coils, friction coefficient, painting systems, fin stabilizers, side thrusters, trim wedges, hull appendages, video eq., hvac chillers, smart cards for cabin energy, propulsion motors, heat recovery, equipment cooling, air supply fans, fresh water generators, adsorption chillers, laundry equipment, heaters, amplifier racks, communication, theatre equipment, elevators, swimming pools, and many many more

70 Energy Power Energy = Power x Time Energy balance = how energy is produced and consumed Electric load analysis = evaluation of energy flows (mechanical, thermal) Too often systems are designed for full power operation They do not work effectively at part load (e.g. slow steaming). This is also true for heat recovery (e.g. low engine load = low heat recovery, oil-fired boilers continuously needed to cover evaporators heat demand)

71 Relative frequency Energy efficiency : how? Passenger Vessel Cruise Profiles Propulsion Power Management P erc entag e of T otal F leet D is tanc e T ravelled with R es pec tive S peed - S ummer S peed [kn] Electric Loads Fresh Water Consumption & Production Black Water Vacuum System Ship Power Station 0.20 Fresh Water Generators Waste Water Treatment 0.15 Alternative 0.10 green power generation New Configuration of Machinery and Aux. Systems Rules for LNG Pax Vessels Dual-Fuel Engines & Systems Design of Dual-Fuel LNG Vessel New Energy Balance Energy Efficiency Design Index (EEDI) 31

72 Hydrodynamic & Propulsion Efficiency Computational Fluid Dynamics / potential / viscous codes Simulation Based Design for numerical optimization Hull forms and appendages Hull surface treatment Propeller / Rudder design Latest piece of this puzzle: five-year term agreement between FINCANTIERI and KRYLOV State Research Center of Russia Joint R&D activities, Realization of new generation products and technical services

73 and more Air Conditioning HVAC is 2 nd energy user after propulsion Fan-coils / adaptive recirculation / heat recovery / natural ventilation Electrical Reduced distribution losses in the network AC vs. DC with variable speed generation and distribution Frequency controlled consumers Lighting - energy and heat efficient, reducing demand for power & HVAC Control Systems & Automation Advanced Integrated Automation Monitoring & Control System for process efficiency and lowest cost operational performance

74 Impiantistica elettrica sulla C.6223 Royal Princess m di cavi m di strade cavi alimentazioni elettriche 510 sottoquadri di distribuzione 33 quadri centralizzati avviatori in apparato motore 16 sottostazioni

75 m di cavi elettrici così ripartiti Miscellaneous 9% Navigation 2% Automation 5% Comm. & Security 40% Local Entertainment System 8% Air Conditioning 7% Lighting 14% LV Distrib. 15%

76 Operation Mechanical & Thermal power originate from fuel Optimum ship operation means fuel saving Focusing on both energy production & consumption Avoiding system operating at low efficiency modes Running devices only when needed Tuning systems to meet actual operation modes Voyage planning / route optimization Training - understanding how any single device affects the whole What is next? Intelligent control system balancing the loading of each component for maximum system efficiency Hybrid auxiliary power generation: fuel cell, diesel generating set and batteries

77 Lessons Learned Ships sharply defined, highly optimized for service profiles Solutions integrated in a comprehensive all-encompassing ship configuration assessment based upon Cost Effectiveness Benefits from partnership shipyard-cruise lines proceeding by steady evolution incremental changes constant improvement 37

78 GREEN Gas Naturale Liquefatto: soluzioni progettuali per navi passeggeri ed interfaccia logistica bordo-terra

79 NOx Limit g/kwh (514rpm) PERCHE IL GAS NATURALE LNG come combustibile consente sensibili riduzioni delle emissioni inquinanti rispetto ai combustibili attualmente in uso (Heavy Fuel Oil, Marine GasOil): - 99% di SOx - 90% di NOx - 20% di CO2-99% di particolato Le normative internazionali impongono limiti progressivamente più severi SOx Fonti: Bob Alton PCL: Emissions Abatement Technology LNG Strategy Miami, March 12 Danish Maritime Autority: North European LNG Infrastructure Project NOx Tier I Tier II Year Global Tier III (ECA) 39

80 PERCHE IL GAS NATURALE Verranno ampliate le aree protette a livello globale Existing or under construction Proposed Marine LNG Terminals Existing Planned Discussed Exisiting & Expected ECA s Fonte: Bob Alton PCL: Emissions Abatement Technology LNG Strategy Miami, March 12

81 PERCHE IL GAS NATURALE Si prevede un trend del prezzo del gas (LNG) inferiore del 30-40% rispetto ai combustibili tradizionali Gli Armatori di navi passeggeri - da crociera e traghetti - chiedono già oggi ai cantieri la progettazione di navi alimentate a LNG / dual-fuel

82 SVILUPPO DELLA PROPULSIONE A GAS NEL NORD EUROPA CONSEGNA NOME ARMATORE LFT COSTRUTTORE 2000 Glutra 122, Bergensfjord 130, Stavangerfjord 129,0 Fjord Raunefjord 130,0 STX Europe-Norwegian Shipyards 2007 Mastrafjord 129, Fanafjord 130, Moldefjord Fjord1 122,2 Remontowa Shipbuilding SA (PL) 2009 Tideprinsen Tide Sjø 50,0 STX France 2009 Tidekongen Tide Sjø 50,0 STX France 2009 Tidedronningen Tide Sjø 50,0 STX France 2010 Fannefjord Fjord1 122,2 Remontowa Shipbuilding SA (PL) 2010 Romsdalsfjord Fjord1 122,2 Remontowa Shipbuilding SA (PL) 2010 Korsfjord Fjord1 122,2 Remontowa Shipbuilding SA (PL) 2012 Landegode Torghatten Nord 93,0 Remontowa Shipbuilding SA (PL) 2012 Vaeroy Torghatten Nord 93,0 Remontowa Shipbuilding SA (PL) 2012 Baroy Torghatten Nord 93,0 Remontowa Shipbuilding SA (PL) 2013 Lodingen Torghatten Nord 93,0 Remontowa Shipbuilding SA (PL) 2013 Viking Grace Viking Line 214,0 STX Finland 2013 Stavangerfjord Fjord Line 170,0 Bergen/Fosen (N) 2013 Bergensfjord Fjord Line 170,0 Bergen/Fosen (N) 2013 NA Tide Asa 124,0 Remontowa Shipbuilding SA (PL) 2013 NA Tide Asa 124,0 Remontowa Shipbuilding SA (PL) 2014 STQ STQ Quebec 130,0 Fincantieri (I) TOTALE 23 Fonte: Bob Alton PCL: Emissions Abatement Technology LNG Strategy Miami, March 12

83 GAS NATURALE LIQUEFATTO: SOLUZIONI PROGETTUALI PER NAVI PASSEGGERI Esistono già normative internazionali specifiche, anche se talvolta riferite al trasporto piuttosto che all utilizzo di LNG: International Code for the Construction & Equipment of Ships Carrying Liquified Gas in Bulk IGC Code; International Code of Safety for Ships using Gas or other low flash point fuels IGF Code & Guidelines, Regolamenti e linee guida dei principali Registri di Classifica

84 IMPIANTISTICA DI BORDO: MOTORI E GENERATORI In produzione tre tipi di motori alimentati a LNG: - Gas-Diesel: funzionamento mediante miscelazione di gasolio e gas o solo gasolio. Ciclo Diesel con l immissione del gas ad alta pressione - Dual-Fuel: funzionamento a gas con 1% di MGO e il restante di gas; può funzionare a solo gasolio. Immissione del gas a bassa pressione. Tali sistemi implicano la presenza di una doppia alimentazione, doppi serbatoi e doppio piping di alimentazione, sistemi di sicurezza per entrambe le alimentazioni - Spark Ignition Gas: L unico combustibile è il gas, la combustione della miscela di gas ed aria avviene in un ciclo Otto, innescata da una scintilla. L immissione del gas avviene a bassa pressione. Source: MAN Diesel & Turbo

85 IMPIANTISTICA DI BORDO: STOCCAGGIO DEL GAS

86 INIZIATIVE DI RICERCA FINCANTIERI PER NAVI ALIMENTATE A LNG Breakthrough in European Ship and Shipbuilding Technologies Studi su sistemi dual-fuel e progetti precompetitivi: nave passeggeri con serbatoi gas orizzontali ferry con serbatoi gas verticali Ministero Istruzione Università e Ricerca PON R&C - Progetto SEAPORT Studio di sistemi per le aree portuali e l interconnessione nave porto finalizzato all'alimentazione di navi bi-fuel.

87 TOTAL ENERGY MANAGEMENT AND ALTERNATIVE ENERGY SOURCES Typical Mediterranean Passenger Ferry LNG as environment friendly marine fuel 4 Wärtsilä 9L50DF Diesel Electric Engines (500 rpm, 50Hz) Vertical LNG tanks

88 TOTAL ENERGY MANAGEMENT AND ALTERNATIVE ENERGY SOURCES 2 independent tanks type C, in accordance with IMO IGC Code Filling and loading limit in accordance with IMO IGF Code. Tot. design pressure = 11.6 bar (g) Design temp. range = C LNG Low Heating Value = 49,2 MJ/kg Inner shell = Austenitic stainless steel Insulation = Vacuum insul. + perlite LNG tank dimensions = 3,6 x 24 m LNG capacity = 2 x 165 m 3

89 Notwithstanding a higher investment, benefits also on NPV KPI Thanks to lower emissions, good performance in all environmental KPIs A ship with traditional E.R 100% HFO B1 ship with Dual-Fuel E.R. 100% LNG B2 ship with Dual-Fuel E.R. LNG 50% HFO 50% Loss of 16 internal cabins

90 traditional 50% LNG 100% LNG traditional 100% LNG 50% LNG

91 traditional 50% LNG 100% LNG traditional 50% LNG 100% LNG

92 traditional 50% LNG 100% LNG traditional 50% LNG 100% LNG

93 100% LNG Innovation effect traditional Trend of positive effects

94 Loss of 16 internal cabin revenue is minimal in comparison with fuel consumption over 30 years LNG + HFO effects to be added together NPV reduced because of LNG propulsion

95 FINCANTIERI C.6239 «GAUTHIER» Matane Baie-Coeau Godbout Ro-Ro Passenger Ferry L=133m, B=22m, T=5m, Vel.20 nodi, 1000 passeggeri, 180 auto Consegna fine 2014 in Canada. Concentrato di tecnologia e innovazione. Standard più evoluti in termini di risparmio energetico e basso impatto ambientale. Propulsione diesel-elettrica, 4 diesel dual fuel (LNG/marine diesel oil) tot. 20,9 MW 2 motori elettrici di propulsione 2 propulsori azimutali, ciascuno con 2 eliche contro-rotanti Capacità di carico / scarico in tempi molto rapidi Certificato con max. classe prevista dai registri e max. classe ghiacci (1 A ed 1 AS)

96 FINCANTIERI C.6239 «GAUTHIER» Matane Baie-Coeau Godbout Ro-Ro Passenger Ferry 35 Nm 30 Nm viaggi/anno = passeggeri veicoli

97 LNG: SVANTAGGI E ALTERNATIVE Svantaggi Potere energetico inferiore ad altre fonti Infrastrutture: effetto NIMBY costo degli impianti, serbatoi, pompe criogeniche, vaporizzatori, stazione di controllo, formazione e professionalità, ecc. Come varierà il costo del gas all aumentare della domanda e della dipendenza? Legislazioni future Alternative Bio-fuels: realtà? quantità? Energie rinnovabili: solare, eolica : quantità? efficienza? Fuel cells: da vent anni saranno utilizzabili tra 5 anni Idrogeno: caro, pericoloso, di difficile stoccaggio Nucleare: dipende dalle politiche Petrolio: da cent anni ce n è solo per i prossimi 20 anni Scrubbers, SCR, filtri: spostano l inquinamento, non lo eliminano

98 Organizzazione aziendale e project management Aspetti generali di progettazione di base di una grande nave Strumenti per la progettazione idrodinamica - simulazioni CFD, ottimizzazione carena ed eliche Progettazione strutturale - analisi statica e dinamica, globale e locale Rumore irradiato in acqua ed in aria Impianti di generazione diesel-elettrica e propulsione aspetti di energy saving e contenimento delle emissioni inquinanti Production Engineering e logistica di produzione

99 Production Engineering (P.E.) processo di industrializzazione integrata del prodotto nave nelle sue due componenti principali: SCAFO e ALLESTIMENTO. Individuazione delle migliori modalità costruttive (risorse Stabilimento e investimenti previsti) Individuazione degli investimenti necessari e/o specifici per la commessa Ottimizzazione costi e riduzione dei TEMPI DI PRODUZIONE - requisiti contrattuali, tecnici, programmatici e di qualità

100 Stabilimento di Monfalcone Principali caratteristiche mq di superficie ( mq coperti) dimesioni bacino: 350 x 56 x 11.3 m 1260 m di lunghezza delle banchine 2 gru a cavalletto di 400t ciascuna, serventi il bacino 2 gru a cavaliere, ciascuna di 1000t, per l area premontaggio 2 gru di 50t ciascuna, serventi lo scalo 11 gru, di portate da 2 a 20t t/anno di strutture d acciaio per carpenteria navale t/anno di strutture navali in lega leggera fino a 2 navi/anno di circa t.s.l.

101 Stabilimento di Monfalcone Flusso produttivo

102 Stabilimento di Monfalcone Officine Scafo Area di stoccaggio lamiere e profili: m 2

103 Stabilimento di Monfalcone Officina Taglio e Sagomatura Impianto sabbiatura e primerizzazione Taglio e sagomatura profili

104 Stabilimento di Monfalcone Officina Taglio e Sagomatura Impianti di taglio lamiere (Plasma e Ossimetanico)

105 Stabilimento di Monfalcone Officina Prefabbricazione Linea pannelli Arco Sommerso

106 Stabilimento di Monfalcone Officina Prefabbricazione Linea pannelli Tracciatura e taglio pannelli

107 Stabilimento di Monfalcone Officina Prefabbricazione Linea pannelli Saldatura automatica profili

108 Stabilimento di Monfalcone Officina Prefabbricazione Linea blocchi piani Robot di saldatura

109 Stabilimento di Monfalcone Nuova Linea Pannelli + Linea blocchi Piani

110 Stabilimento di Monfalcone Officina Prefabbricazione Area Blocchi piani, curvi e speciali

111 Stabilimento di Monfalcone Officina Allestimento Sistema ribaltamento blocchi

112 Nuova Area Premontaggio e Preallestimento 2 nuove gru a cavaliere, ciascuna di 1000t.

113 Stabilimento di Monfalcone Officine Montaggio Assemblaggio Sezioni di Montaggio

114 Stabilimento di Monfalcone Officine Montaggio Nuova area PREMONTAGGIO

115 Stabilimento di Monfalcone Officine Montaggio PREMONTAGGIO SCAFO

116 Stabilimento di Monfalcone Imbarco in bacino

117 Stabilimento di Monfalcone Ciclo di produzione nave (teorico) Progettazione costruzione scafo montaggio impianti montaggio arredo Ciclo di produzione reale Progettazione contrattuale + modifiche costruzione scafo montaggio impianti montaggio arredo

118 Stabilimento di Monfalcone Documentazione a. Documentazione PLA (piani di montaggio esecutivi, liste tubi, disegni progettuali di dettaglio, disegni di arredo...) b. Documentazione MET (piani di premontaggio blocchi e sezioni, P.E. di allestimento, Fire Prevention Plan, Sistemazione impianti provvisori, programma imbarco cabine, istruzioni di lavoro )

119 Stabilimento di Monfalcone PLA / Piani di Montaggio Si sviluppano sulla base dei piani coordinati, i quali sono a loro volta figli degli schemi di montaggio (unifilari) dei vari impianti, emessi dalla progettazione funzionale.

120 PLA / Disegni di arredo Stabilimento di Monfalcone Si sviluppano sulla base dei piani generali, dei concept drawings dell architetto di S.A., etc.

121 Organizzazione aziendale e project management Aspetti generali di progettazione di base di una grande nave Strumenti per la progettazione idrodinamica - simulazioni CFD, ottimizzazione carena ed eliche Progettazione strutturale - analisi statica e dinamica, globale e locale Rumore irradiato in acqua ed in aria Impianti di generazione diesel-elettrica e propulsione aspetti di energy saving e contenimento delle emissioni inquinanti Production Engineering e logistica di produzione Considerazioni finali

122 Safety regulations Continuously updated Learning from past accidents Preventing future problems Examples Safe Return to Port, Formal Safety Assessment, Alternative Design, Fire Prevention, Time to Flood-Sink-Capsize, Water on Deck, Goal-based / Performance-based Design, Probabilistic Damage Stability, New Generation Intact Stability Criteria, Innovative Life-Saving Appliances, Evacuation Analysis, Pollution Prevention and Control, Collision & Grounding, Navigation & Bridge Equipment

123 New regulatory framework: Consequences on cruise market development Significant evolution in newbuilding designs New prototypes Higher production cost (generated by new regulations) Higher costs for smaller vessels Prices cannot easily be driven downwards: Yards already at cost Financing much more difficult and costly than before Increased demand for conversions & refitting

124 R&D SHIPBUILDING REGULATORY FRAMEWORK New operational requirements foster new designs which have to comply with new rules & regulatory changes Goal Permit innovation in design

125 MAIN DRIVERS OF INNOVATIVE DESIGN safety business environment new technology

126 Future Designs & Sustainability New rules & regulations: exploiting new design opportunities New technologies: impact on systems, interfaces, lay-outs, arrangements Cruise ship design is big puzzle: if the shape of one piece changes, all the adjacent change accordingly Impact on design: non linear, not simply the addition of all factors Next generation design: finding the right balance on business / safety / environment The role of applied research and innovation