Professional Documents
Culture Documents
2017
PUBLIC-PRIVATE
PARTNERSHIPS
THE SILK ROAD
REVIVAL BRAZILIAN TREASURES
Power prospects for A new logistics route Transforming the oil and gas industry through
Senegal opens up to China reforms and international partnerships
NO 02.2017
DEAR READERS,
As First World inhabitants, we take a lot for granted. It is
TURBO
only when we deliberately move the curtains aside that we dis-
cover the background machinery that so smoothly maintains
our privileged existence. The curtain we have peeked behind
in this issue covers the amazing work of the navy. We jumped
at the chance to visit the HNLMS Holland, a Dutch Navy
offshore-patrol vessel, and were impressed by the personal com-
mitment, professionalism and teamwork of a crew whose chal-
lenges range from chasing drug traffickers to helping hurricane
victims – all in a day’s work.
Another article in this issue has historic roots that can be
traced back to Marco Polo, the great explorer. In the 13th century
he traveled on the so-called Silk Road from Europe to China, one
of the world’s most ancient trade routes. With the rise of global
shipping, its significance faded, but it is now about to undergo a
resurgence with heavy Chinese investment into the Iron Silk
Road – a new European rail connection to China. To learn more
about the future possibilities for this historic route, we sent our
technology, equipped with state-of-the-art sensors, on a 16-day
trip through the heart of continental Europe and Asia.
On our final journey, rugged green mountains meet bar-
ren Caribbean landscapes when we contrast two equally isolated
spots at opposite ends of the world: the island of Bonaire and the
Faroe Islands. As distant and different as they are, they have one
thing in common: both operate one of the world’s most ad-
vanced hybrid-energy systems. As you will see, there is a lot to
learn from these smart islands.
We were I hope you will enjoy the journey we are about to take you on.
the personal
commitment.” Dr. Uwe Lauber, CEO of MAN Diesel & Turbo
MASTHEAD: MAN MAGAZINE is published two times a year in English. · PUBLISHED BY MAN Diesel & Turbo SE, Dr. Jan Dietrich Müller, Group Communications & Marketing,
Stadtbachstr. 1, 86153 Augsburg, Germany · Editors in Chief: Jan Hoppe (jan.hoppe@man.eu), Felix Brecht (felix.brecht@man.eu) · PUBLISHER C3 Creative Code and Content GmbH,
Heiligegeistkirchplatz 1, 10178 Berlin, Germany, Tel.: +49 30 44032-0, www.c3.co · CONTENT DIRECTOR Klaus-Peter Hilger · EDITORS & AUTHORS Cedric Arnaud, Deborah Capras
(responsible), Kirti Letsch. Freelance author: Eamonn Fitzgerald · COPY EDITOR Asa Tomash · PROJECT MANAGEMENT Christa Krick · GRAPHICS Charlotte Bourdeix, Michael Helble,
Andrea Hüls, Christian Kühn, Linda Lorenz · PHOTO EDITOR Elke Latinovic, Samantha Taruvinga · COVER IMAGE Hilaea Media/Dado Galdieri · PRODUCTION C3 Creative Code and Content
GmbH · PRINTING Pinsker Druck und Medien GmbH, Pinskerstraße 1, 84048 Mainburg, Germany · REPRODUCTION permitted with reference. Any changes must be coordinated with the
editors. · COPYRIGHT ©2017 MAN Diesel & Turbo and C3 Creative Code and Content GmbH. All information provided in this magazine is intended for general guidance only and is not
intended to be used as a substitute for specific technical or commercial information and advice.
02
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10
A SECTOR OPENS UP IN BRAZIL
14
40
22
CONTENTS 10
04 Dual leaders
MAN and hybrid propulsion specialist AKA have
joined forces.
06 MY MAN
Kenya: the geothermal superpower
PHOTOS: Simon Katzer, shutterstock, Paul Langrock/Zenit/laif,Henri-Jean Vittecoq, Hilaea Media/Dado Galdieri
08 TURBO
Subsea technology goes topside
A multitalent and a breakthrough in offshore 32 MARINE
Fueled for change
compression: the Ivar Aasen oil platform. Moving forward toward eco-friendly marine
10
transport: freighters powered by LNG.
Tapping the treasures of the deep
Vast deposits and major reforms are attracting
international players in the oil industry to Brazil. 34 Powered up, on patrol and mission ready
On board the HNLMS Holland for counter-drug,
14
anti-piracy and humanitarian missions.
Rebooting the Silk Road
Why the modern Iron Silk Road works as a viable
alternative for transporting goods to China. 40 Offshore turbines: up and turning
Facing the challenges of the forces of nature with
engineering, expertise and advanced equipment.
20 POWER
Remote power
As no roads lead to the Amazonian city of Iquitos, 44 DIALOGUE & OPINION
“It’s not a revolution yet!”
commissioning a new power plant was a challenge. How far can 3-D printing change manufacturing,
22
and who stands to benefit in the future?
When the World Bank has a say
How public-private partnerships are improving
the power prospects for Senegal. 46 News & facts
Brief business updates.
03
NO 02.2017
DUAL
▲
The “Deepwater Thalassa”: the
world’s first hybrid drilling vessel.
Among other improvements,
AKA technology ensures fuel
savings of over 40%.
▲
Jason Aspin: leading
the switch to electrical
systems with smaller
carbon footprints.
LEADERS
The fast-evolving transition to decarbonization and digiti- er and hybrid power and propulsion solutions. So, it is a win-
win set-up, and, yes, you could say, a match made in heaven.
zation requires strong partnerships. In 2017, MAN Diesel &
Turbo acquired a 40% stake in Aspin Kemp & Associates How will your customers benefit? What does this part-
(AKA), a specialist in electric and hybrid systems. Jason nership essentially bring to the table? This is a partner-
Aspin, co-founder and Managing Director, reveals why the ship between a larger, established and global-oriented
group, a specialist manufacturer of diesel and gas engines,
tie-up works for both parties – and for customers. and a small, nimble and agile company, a specialist in high-
reliability power, hybrid technology and energy storage sys-
How would you describe the partnership between your tems. This partnered approach will enable us to develop new
company and MAN Diesel & Turbo SE? Is it a match made applications on a larger scale. Particularly when it comes to
in marine-power heaven? For many years, we have been marine propulsion, we see a distinct advantage to this tie-up
struggling with what would be the ideal strategic partner. As for clients. Together, we will link up the MAN Diesel & Turbo
a small company, it’s hard to compete against larger organi- expertise in engine technology with our knowhow in ener-
zations, even though we might have a superior technical solu- gy storage and energy management systems. This combina-
tion. The industry trend is also moving towards complete tion will lead the industry in improvements in reliability
packages, so we need to be able to deliver such solutions. The and safety, and to reduced emissions. There are lots of areas
competences of MAN Diesel & Turbo in the fields of engines, where we will be able to leverage this relationship to build
exhaust gas after-treatment, and gas and propulsion systems the solutions our customers seek. Solutions that would have
complement our expertise and technology in electrical pow- been more difficult to deliver separately.
04
NO 02.2017
How so? If you look at how the market is developing and the added value of an IoT solution does not lie so much in detailed
challenges our customers face, there is a lot of insecurity insight into the operational status of each and every asset. It’s
about the future. In the face of tightening emission regula- the overall system he is interested in. So this is where we are
tions, being a trusted OEM who provides components is trying to take things. MAN Diesel & Turbo provides the adap-
not good enough anymore. We need to be trusted advisors, tive knowledge on the engine side, and we can combine that
too, and not only offer optimization of isolated components, with our knowledge of power and automation systems. Such
but also look at power and propulsion from a systemic a combined offering of digital solutions has the potential to
angle. Clients need partners who offer integrated solutions drive efficiency, reduce costs and improve reliability.
tailored to their specific challenges. Our area of expertise is
integration, pulling different components together and Your first joint project will be to supply a diesel-electric
making them work as a single system. This joint expertise propulsion package for a multipurpose supply vessel –
allows us to offer the guidance and system approach our can you tell us little more about the project? We are really
customers expect. looking forward to successfully getting it out the door and
Jason Aspin
sition, a global shift to gas as a fuel to reduce emissions
from shipping. What is your take on the subject? With the
Paris Agreement in place, the maritime industry – like any
other – has to reduce its carbon footprint. If we are to make
Jason Aspin is the co-founder and Managing director of Aspin Kemp &
this work and reach climate neutrality by 2050, everyone
Associates, a systems integration and technology company specializing
needs to chip in. MAN has been a real driver behind the
in power supply, energy management and drive systems for marine
move towards more eco-friendly propulsion systems in
applications. Based in Montague, Prince Edward Island, Canada, it is
shipping, both technically and – especially lately – also on a
the world market leader in equipping diesel-hybrid-powered ship
political level. From our side, since we founded the company propulsion systems with integrated battery storage and high-reliability
just over 20 years ago, we have always focused on developing onboard power systems in dynamic-positioning applications for the
technology to reduce environmental impact, increase reli- marine and offshore oil and gas sectors.
ability and safety, while reducing operating costs. So in a
way, both companies have been driving the energy transi-
tion, just from different ends. The transition will continue
to change and morph as we go forward, but together we are
even stronger leaders in this movement. being able to demonstrate how we can seamlessly put togeth-
er a complete package. The key to its success is developing an
Next to decarbonization, digitization is a major trend. AKA/MAN solution that provides all the reliability and effi-
How will it change the industry? There is a lot of focus on ciencies of AKA’s successful power solutions in a power and
digitization right now. But it often lacks direction. I’m confi- propulsion package. Lower fuel consumption, maintenance
dent that together we will be able to provide this direction. costs and emissions will be the result. Our expertise in ener-
Essentially, we will bring more clarity on how data can be gy management and electrical-system integration, combined
used to provide real value to the owners. This will involve with the vast experience in power-train solutions on the side
capturing and combining all the data that both companies of MAN Diesel & Turbo, allowed us to deliver together a
have access to, and then figuring out what questions we need completely integrated power and propulsion system for this
to ask of this data to bring value to the operators. Most cus- vessel. The project is moving along well. We’re expecting
tomers are looking for partners here, not companies that tell to be in operation around mid-2018.
them what they need. Customers have valuable process
knowledge and problems that can be solved within the data How do you see the long-term impact of this partnership
that is available. We believe that a successful model involves with MAN Diesel & Turbo? I see us as joint leaders in tech-
a systems-based, iterative approach, with significant custom- nology and engineering, developing new solutions, solving
er and stakeholder participation. Everyone is trying to offer problems that are out there now, and building a basis for
PHOTOS: aka-group.com
their solution to this, but the provided packages are often of tackling future ones, too. We will push the limits as far as the
more value to the OEM than to the owner, as they lack a technology goes. Decarbonization and digitization present
systems approach. Each operator is running a multitude of all kinds of challenges, and if we are perceptive and flexible,
assets, from a multitude of OEMs, on each of his ships. The we will be able to master them for our clients. ▪
05
NO 02.2017
PETER
CHEGE
ASSISTANT MANAGER AT
THE KENYA ELECTRICITY
GENERATING CO. LTD.
06
NO 02.2017
PHOTOS: Green Energy Geothermal (GEG), KenGen Press
MY MAN
KENYA:
1
THE GEOTHERMAL
SUPERPOWER
The breathtaking Great Rift Valley was formed by volcanic
activity, trapping hot steam in the rocks. Today, KenGen, the
Kenya Electricity Generating Co. Ltd., is tapping into this renew-
able source of energy that is attracting worldwide attention.
Peter Chege, you are responsible for the 14 plants with a total
of 75 MW wellheads turbo generators at the Olkaria geother-
mal power fields, 130 km from Nairobi. Why is geothermal
power crucial for Kenya? In the past, our country relied very
much on hydro; it accounted for 50% of installed capacity. But
constant and recurring droughts have made hydropower ex-
tremely unreliable. By moving into geothermal, diversifying
away from hydro, we’ve reduced our country’s vulnerability to
changes in the weather. Kenya was the first to adopt geothermal
1 power in Africa, and we are now ranked the eighth-largest pro-
The 75 MW wellheads ducer of geothermal energy in the world. We expect to push the
at the site of Olkaria:
commissioned in installed geothermal capacity to 1,000 MW by 2020.
2017 and expected to
provide 14% of
Kenya’s power. There must be challenges too. The most difficult and capital-
intensive part is the drilling of the wellheads. It can cost around
2
Peter Chege at the $6 million for each one. Once the wellhead is up and running, the
controls: monitoring
return on investment is within ten years. It’s truly a reliable
the performance of the
MAN steam turbines. source of renewable energy, and there’s no waste. It provides us
with a baseload supply with a very small carbon footprint.
07
08
NO 02.2017
PHOTO: Aker BP
NO 02.2017
SUBSEA
TECHNOLOGY
GOES TOPSIDE
◀
Breakthrough in offshore The 19th-century Norwegian philologist, lexicog-
compression: The
“Ivar Aasen” features rapher, playwright and poet Ivar Aasen can only
MAN’s HOFIM™ system. be described as a true multitalent. Best known
for the creation of Nynorsk – one of the two offi-
cial written versions of the Norwegian language –
he is also a fitting namesake to the new offshore
production platform run by Aker BP in the Nor-
wegian North Sea.
09
NO 02.2017
TAPPING THE
TREASURES
OF THE DEEP
The vast hydrocarbon reserves off the coast of
Brazil are attracting international organizations
and a global pool of expertise.
10
NO 02.2017
◀
The FPSO “Cidade de
Mangaratiba MV24”
undergoing checks at
the Brasfels shipyard in
Angra dos Reis, Brazil.
▶
Fernando Coelho Filho,
the Brazilian Minister of
Mines and Energy,
at an auction of the
offshore concessions.
Brazil’s most prized treasures lie 450 km off the coast of Rio
de Janeiro, far beneath the ocean floor, at a depth of around
2,400 m, trapped beneath thick 2,000-meter layers of salt.
Cracking through the compound reveals a huge network of
valuable hydrocarbon deposits. Discovered only recently, in
2007, they are known as the pre-salt fields. These giant
deep-water offshore reserves in the Campos and Santos
Basins are so vast that it requires strong partnerships, an
immense pool of skills and advanced technology to exploit
the area’s full potential. In an initiative to speed up oil and
gas exploration in the area, the Brazilian government re-
cently opened up the sector for international companies.
The auctions are attracting interest from major players in
the industry.
“This is still one of the world’s most attractive
oil fields,” says Jens Hueren, Managing Director at MAN
Diesel & Turbo, Brazil. “Now that the regulatory changes
are opening up the sector, it’s a promising area for major
oil companies to invest in. It is no longer the case that
Petrobras, the state-owned energy company, has to hold a
PHOTOS: Hilaea Media/Dado Galdieri, gettyimages
11
NO 02.2017
“CIDADE DE
low, in the double hull. After processing, the oil or gas is
offloaded via either shuttle tankers or pipelines. “The FPSO
MANGARATIBA MV24”:
150,000 barrels
of oil per day
280 million standard
cubic feet of gas per day
1,600,000 barrels
storage capacity
◀
The process system is divided into
topside modules on the FPSO, while
oil is stored below in the double hull.
12
Espírito Espírito Santo Basin
Santo
Brazil State
An attractive prospect
Discovered in 2007, the estimated
reserves of tens of billions of barrels
of crude lie around 450 km off the
coast of Rio de Janeiro.
Rio de Janeiro State
Rio de Janeiro
São Paulo State
Guanabara Bay Campos Basin
São Paulo
SOLID
PARTNERSHIP
Oil fields
150,000 barrels a day! Any downtime can influence the pro- sophisticated type of equipment and technology needed to
duction and become very expensive.” In other words: Oil adequately exploit the reserves, given the highly complex
and gas have to flow, so the pre-salt investments pay off for vessels and infrastructure needed. As the international
Brazil, and also for each of the international partners. presence in the area increases, it will ultimately contribute
In Brazil, expert support is provided by the MAN to the transformation of the market. For the benefit and in
PrimeServ hub in Petrópolis. In 2012, MAN PrimeServ Brazil the interests of everyone involved. ▪
13
NO 02.2017
REBOOTING
THE
SILK ROAD
14
NO 02.2017
The ancient Silk Road interlinked China to This Iron Silk Road will basically con-
Europe, India and Persia, bringing spices and sist of three rail corridors. Two are active al-
supplies as well as the finest of silk to new ready, while the southerly route is currently
markets. From the third century, for over a under negotiation and construction. Howev-
thousand years, this trail was a valuable er, it’s the main central corridor that provides
source of commercial and cultural treasures. the shortest, most efficient crossing from
Primarily about trade, it also provided a plat- Western Europe to central China. Starting
form for the exchange of ideas, knowledge, from Duisburg, a major transport hub in Ger-
traditions and belief systems. However, it many, this particular corridor stretches over
wasn’t in fact a single pathway as the name 10,000 kilometers, across six diverse coun-
suggests, but a complex network of multiple tries and vast unpopulated areas, all the way
transport routes, linking villages, towns, oa- to the megacity of Chongqing, southwest Chi-
ses and cultures. It grew in a flexible, organic na. As Duisburg is located only kilometers
way out of economic demand, necessity and away from MAN Diesel & Turbo’s main pro-
opportunity. Today, around 1,000 years after duction plant in Oberhausen, Germany, this
its heyday, such flexible complexity is pro- particular corridor has opened up a quite di-
viding inspiration for a modern revival of the rect train link to the company’s main pro-
Silk Road. Officially called “The Silk Road Eco- duction site in China. One that provides an
nomic Belt and the 21st Century Maritime interesting logistics option.
Silk Road,” this ambitious initiative goes
more commonly by the name “One Belt, One FREIGHT GAINS
Road” (OBOR). Launched in 2013 by Chinese “Sea freight is the cheapest mode to
President Xi Jinping, OBOR is not just about bring goods to China, most flexible from size,
creating one route, but instead involves a too. But often it’s too slow,” says Dirk Petzold,
huge investment in intercontinental infra- Head of Logistics and Plant Services, MAN
structure that will create multiple trade cor- Diesel & Turbo in Oberhausen. “Air freight is
ridors and hubs overland, maritime routes fast, flexible time-wise, but very limited by
PHOTOS: James Hill/laif, ullstein bild /SPUTNIK, shutterstock
and ports, as well as oil and gas pipelines size. And expensive. With air freight, we
across the Eurasian continent. Of all the found that the additional costs were mostly
routes that are being expanded, however, it is not in relation to our delivery requirements.
essentially the preferred mode of transport We often don’t need such a speedy delivery.
from the 19th century that is making a com- We needed something in between, and the
pelling comeback: rail. Iron Silk Road offers a viable alternative.”
15
NO 02.2017
Day 1
Duisburg
THE EUROPEAN GATEWAY
The main production site in Oberhausen is China’s deep central region to Europe, on
just a short truck ride to Duisburg, where a trains run by the state railways of China, Ka-
long train journey through the gateways of zakhstan and Russia. As the railway gauges
China and on to Wuhan starts, followed by are not yet harmonized along the route, con-
another, longer truck connection to Chang- tainers have to be offloaded at the Russian
zhou, where the China plant and regional borders, in Belarus, and again on arrival at
We used
base for the Chinese market is located. the Chinese border. Despite these short inter-
Taking this route, rail freight passes ruptions, the train journey is otherwise di-
IoT technology
through Poland, Belarus, the Russian Steppe, rect and seamless. The accelerating speed of
Kazakhstan, the Gobi Desert and connects trains, upgraded infrastructure and seamless
to monitor
position, shock
and humidity.”
Dirk Petzold, Head of Logistics and Plant Services,
MAN Diesel & Turbo in Oberhausen
Day 5
Russia
ACROSS THE STEPPE
16
NO 02.2017
Belarus
TRANSSHIPMENT HUB Day 3
logistics coordination are expected to drive logistic route,” highlights Stefan Hütten, number of trains arriving at Duisburg from
further improvements in the future. It’s a Authorized Officer at duisport agency, a lo- China has increased from just one a week to
journey that now takes around 16 days. Just gistics partner of MAN Diesel & Turbo and in- about 30 a week. “Freight rail service between
ten years ago, it took more than 30. In com- frastructure provider based out of Duisburg. continents is completely new, and in some
parison, goods on the more circuitous route “As part of the One Belt, One Road strategy, ways still in the initial phase,” says
by sea from Shanghai on the Pacific Coast to it’s an integral part of a complex supply chain Hütten. “But we believe in OBOR.” As a hub-
Hamburg on the North Sea would cover more pushed and powered by the Chinese gov- and-spoke system, Duisburg is the most
than double the distance, around 25,000 km, ernment. It offers a small, important niche important point in Europe with regard to the
and still take at least four to six weeks. between air and sea freight.” Since the inau- OBOR strategy, which makes it an attractive
“The Iron Silk Road is more than just a guration of the route four years ago, the gateway for MAN Diesel & Turbo.
PHOTOS: Oliver Tjaden/laif, MAN, ullstein bild /SPUTNIK, shutterstock(2)
Kazakhstan
TRANSSHIPMENT HUB Day 11
17
NO 02.2017
Northern China
Day 12 -20 DEGREES CELSIUS
PRODUCTION INROADS
The Iron Silk Road is
more than just a logistics route.”
Petzold had been monitoring the de-
velopment in freight opportunities from Eu-
rope to China for several years, before decid-
ing to introduce it as an in-house logistics op- Stefan Hütten, Authorized Officer at duisport agency
tion. Until fairly recently, trains returned to
China less utilized. The decision to adopt rail are significantly fewer connections still, and cant economic growth along the whole net-
followed extensive real-world tests over a six- rail cannot handle oversized shipments. “It is work. Although mainly a stimulus campaign
month period, to learn about the hurdles and a logistic solution with promising future,” to modernize the Chinese national infra-
opportunities. “We used a new upcoming says Chengke Shao, Head of Logistics and structure, it is acting as a bridge for partner-
sensor tag based on IoT technology to moni- Planning at the MAN Diesel & Turbo plant in ships with other nations. The geographical
tor geographic position in near time, tem- Changzhou. “For oversize goods, however, the area that could potentially be involved is
18
NO 02.2017
Gobi Desert
UP TO +40 DEGREES CELSIUS Day 13
Chongqing
LOGISTICS HUB Day 16
19
NO 02.2017
▶
The Iquitos power
plants amid
tropical rain forest.
20
NO 02.2017
REMOTE
POWER
Other than a 65-mile, dead-end stretch to the
town of Nauta, there are no roads leading in or out
of the Amazonian city of Iquitos. Only the river
and a small airport provide access to Peru’s largest
and most isolated jungle town. Due to its remote
location, the city is not connected to the national
power grid. And while plans to connect Iquitos
via an electricity transmission line that would
run for approximately 586 kilometers through
the Amazon exist, they have been delayed in-
definitely due to environmental concerns and
disputes over indigenous territory rights.
21
NO 02.2017
per annum:
the paper supports the idea that the private sector can
successfully participate in financing, building and main-
Electrification of
the country:
26%
Number of
participating
countries:
13
Number of
suppliers:
70
22
NO 02.2017
◀
MATELEC CEO
Sami Soughayar
(second from
left) with Presi-
dent Macky Sall.
SAINT-
NAZAIRE
WHEN THE
WORLD BANK
HAS A SAY
PHOTOS: Henri-Jean Vittecoq
23
NO 02.2017
◀
Seven bridges were
removed to transport
the engines the 90 km
from Dakar to the site.
Speed limit: 15 km/h.
Time needed: 24 hours.
A moment to celebrate:
the arrival of the first
MAN 18V48/60 engine
at the site.
▼
AUGSBURG
BEIRUT
important for the private sector to participate. As public- commitment and confidence in the project.” It worked.
private partnerships (PPPs) have reduced project costs and MATELEC will manage the power plant for the next 20 years
expanded coverage in other regions, including Brazil and and will sell the power to the national energy company
Peru, the report proposes that the same is possible in Africa, Senelec as a way to finance their own investment and to
where two in three people still live without access to elec- serve the long-term loans.
tricity. Private capital has led to positive results, thanks to
financial guarantees, the World Bank experts summarize. FINANCING WITH CONDITIONS
The new 115 MW Tobène power plant covers about Sami Soughayar, MATELEC’s CEO, explains the diffi-
20% of the energy of Senegal and is a prime example culties in building a power plant in the developing African
of how such a PPP can deliver. It was not built by the nations. “The World Bank looks at all aspects of a project,
state-run energy company Senelec. And operations are not down to the smallest of details. Was the contract award
managed by a public entity either. Instead, the Lebanese transparent? Did we adhere to environmental and compli-
power plant specialist MATELEC successfully built this new ance rules and regulations? Is the network infrastructure
electricity-generating plant as a so-called independent sufficiently developed? Can we secure long-term fuel sup-
power producer (IPP) in close cooperation with MAN. Proj- ply? In a nutshell, the power plant has to be able to operate
PHOTOS: Henri-Jean Vittecoq (2)
ect manager Pierre Morantin of MAN Diesel & Turbo France sustainably over the life of the contract, even if the political
explains: “This is a turnkey power plant. The investment of framework changes locally.” This means that the Senegalese
€120 million has been financed to 80% with a World Bank government had to make guarantees and adjust the legal
loan. The highly energy-efficient DCC technology was es- framework accordingly. And this is not common practice,
sential to secure this funding. The remaining 20% will as Soughayar reports: “In some countries, the local govern-
come from private investors at MATELEC, as a sign of their ment cannot handle these complex processes, as it seems
24
NO 02.2017
40,000
Weight of one
single engine:
320 metric tons
Cement used:
6,000 m3
Manpower used:
50 technicians and
engineers from
MAN Diesel & Turbo
◀
Powerful together: The five
MAN 18V48/60 engines and
the MARC steam turbine
generate up to 115 MW.
25
NO 02.2017
SHINING
A LIGHT
ON SMART
ISLANDS
Self-sustaining islands need innovative energy solutions.
Two remote islands on opposite sides of the planet are
true pioneers in the area. Smarter integration of natural
resources is the key to their success.
26
NO 02.2017
◀
Strategically placed
wind turbines over
the Faroe Islands
have a capacity of
18.6 MW.
PHOTOS: Ólavur Fredriksen, Pauli Djurholm
▶
The Sund power
plant near Tórshavn:
Four MAN 9L51/60
GenSets provide an
output of 37 MW.
27
NO 02.2017
2 3
As a power company,
we cannot compromise on
the security of the power
supply for all our customers.”
Terji Nielsen, research and development manager at Elfelagið SEV, Faroe Islands
28
NO 02.2017
3
Terji Nielsen, research
and development man-
ager at Elfelagið SEV:
Integration of renew-
able energy to the grid
is his expertise.
4
Another first: a 2.3 MW
lithium-ion battery,
installed in 2016, will
support the ambitious
target of 75% wind
penetration by 2020.
60
4
PERCENT
ideal kind of test lab. New technology can be tried out, be-
cause the impact is measured quickly and reliably. In 2016,
of electricity currently generated from Europe’s first wind-connected storage system, a 2.3 MW
renewables on the Faroe Islands lithium-ion battery, was installed here, and will significant-
ly contribute to reaching the target of 100% wind penetra-
tion by 2030. In the future, the company is looking into
even more intelligent control systems that will accurately
predict renewable power generation – whether wind, solar,
hydro or tidal – for a 20-hour period, helping define which
thermal power plant is needed, and automatically choosing
FAROE
ISLANDS the cheapest source with the lowest marginal cost. “Engine
power plants are definitely a bridging technology to green
generation,” Nielsen says.
Yet their role has changed: “From ‘baseload back-
PHOTOS: Ólavur Frederiksen (3)
29
NO 02.2017
1
97
PERCENT
availability of engines and wind turbines
2
3
1
The pristine coastline
is attractive for diving
enthusiasts, but also
an ideal location for a
wind farm.
2
It doesn’t get much
more remote and iso-
lated than this: Bonaire
is dry, barren and
windy most of the year.
3
Even in perfect weather
conditions, three of the
five MAN engines are
constantly connected
to the grid.
30
NO 02.2017
tilles, located in the Caribbean just 85 km off the coast of and October on Bonaire, wind penetration is zero. There is
Venezuela, Bonaire is dry, hot and barren. With cacti. But virtually no wind at all. It’s why an extension to the power
when it comes to green energy, it’s truly a pioneer. Much plant could only include more diesel engines,” explains
like on the Faroe Islands, the local economy also depends on Narminio. “Without the diesel back-up, the island wouldn’t
the environment. Some 50,000 tourists, predominantly on have a stable supply of electricity.” It would be plunged tem-
diving trips off the pristine coastline, are important for the porarily into darkness.
livelihoods of the 16,500 locals. But it’s mainly wind and As is the case on the Faroe Islands, the purpose of the
diesel, not hydro or solar, that power this community. engines is to support the stable and reliable grid. Thanks to
In 2013, ContourGlobal took over the operation of the the continuous improvements by ContourGlobal, the last
world’s largest wind-diesel hybrid power plant of its kind. It’s major outage was back in 2015. “We achieve over 97% avail-
the sole power generation facility on the island and a major ability of the engines and the wind farm, providing the is-
engineering achievement in integrating wind and diesel lands with a most reliable and stable system,” highlights
power. Giorgio Narminio, Caribbean Assets COO at Contour- Narminio. “We have the technical, skilled people who have
Global, is convinced of the hybrid solution. It’s crucial not made a difference to the service here.”
only for protecting the environment, but also for a reliable
grid: “Integrating wind power saves an estimated 54,384 bar- A FLEXIBLE, RESILIENT RESPONSE
rels of heavy fuel oil a year,” he highlights. “But even when In moving away from hydrocarbons toward more
the wind conditions are good, three engines are constantly sustainable sources of power, smart islands need to be able
on the grid. The MAN engines keep the reactive power in to meet the challenge of a fluctuating power supply from
good shape and maintain a stable grid and frequency.” renewable sources and a fluctuating power demand from
The essential back-up that keeps the holiday resorts the consumer side. It is this intermittency of renewables,
lit up and running, whatever the wind and weather, com- particularly wind power, that demands a flexibility of re-
prises a fleet of five MAN 9L27/38 2.87 MW diesel engines, sponse from other energy sources on the grid, says Meyers.
while 12 Enercon E-44 900 kW wind turbines provide the “The MAN engines rapidly step in to supply power when
wind power. A 3 MW battery bank and a bespoke power needed, and are throttled back when wind or solar condi-
management system complete the advanced set-up. It sup- tions improve. This kind of system is able to adapt to the
plies the island, roughly 288 square km, with an output of prevailing climatic conditions – instantaneously.”
up to 28 MW gross capacity of environmentally friendly en-
ergy, with 14 MW peak capacity. For 2017, it’s predicted to THE POWER OF THREE
provide 110 GWh, 35 GWh of which will come from wind. Although these two smart island communities are in
Why five engines? They offer a more flexible and ef- very different situations, it’s clear that three factors have
ficient option than one large one. Although Bonaire could, played a role in moving toward more stable, climate-
in theory, produce up to 90% of their power with wind, the neutral energy production: the culture of the society, the
grid would become too unstable. For this reason, wind pow- natural environment and an innovative mix of technology.
er is capped at 70% to 75%. At least 30% of power always Hybrid power plants are clearly a central growth technolo-
comes from the engine power plant. Bonaire is close to the gy on this pathway. The result: sustainable micro grids that
equator, so fortunately it’s not affected by hurricanes. How- are powering islands on opposite sides of the North Atlantic
ever, the winds can be extremely strong, and they are also Ocean, providing role models for every community. ▪
31
NO 02.2017
▲
The world’s largest
transit point for car
shipments.
32
NO 02.2017
FUELED FOR
CHANGE
The world’s largest parking lot can be found in one
of Germany’s oldest trade ports – Bremerhaven.
Up to 95,000 cars find a space here, awaiting their
turn to be transported to destinations all over
the world. A total of over 2 million vehicles are
shipped from Bremerhaven every year by all
major German car manufacturers – Volkswagen
(VW) among them. As the shipping of cars from
one continent to the other contributes its share
of emissions, VW – as one of the first OEMs – has
decided to significantly improve the environmen-
tal balance of its marine transport fleet.
▲
A milestone on the way to
eco-friendlier marine transport:
LNG-powered freighters.
33
T
NO 02.2017
POWERED UP,
ON PATROL AND
MISSION READY
The HNLMS Holland is designed, powered and crewed
for counter-drug, anti-piracy and relief missions.
A trip on board reveals the precise interplay of training,
technology and teamwork in the Royal Dutch Navy.
34
NO 02.2017
◀
Boarding the vessel
from the NH-90
helicopter requires a
steady hand and
ship.
On the lookout:
ready for a rapid
and coordinated
response.
▼
We can achieve
much more together than
we can individually. It’s
worth a lot to me that the
team works well together.”
Captain van Zanten, HNLMS Holland
35
NO 02.2017
3,000
and teamwork is essential for success – and safety. “When
we are on an actual mission, it’s even more important to
promote the team spirit than it is right now,” says Captain
Jeroen van Zanten, the commanding officer.
1
No chance to escape:
MISSION ACCOMPLISHED When the FRISC
launches, the target is
KG
The crew’s advanced training is crucial for such ma-
soon in sight.
neuvers, and also guarantees the flexibility needed on real
2
missions, which include independent anti-piracy and Relief supplies at the
counter-terrorism operations, but also deployments as a ready: Supporting the
of cocaine seized
islanders on Haiti was
support vessel for the Dutch marines at sea or in sea-to- a rewarding mission for
shore operations. That agility is constantly put to the test. everyone on board.
In September 2016, for instance, the HNLMS Holland set sail
for the Caribbean, and was scheduled to pull into the Dutch
off Curaçao
naval base on Curaçao on a counter-drug deployment. As
they were underway in the North Atlantic, Hurricane Mat-
in three months
thew hit Haiti hard, causing major destruction across the
island, which had already been devastated by an earth- meant that we could make a difference fast.” Over 21 days,
quake only six years before. The islanders were in dire need they brought in 450 metric tons of relief supplies to land.
of support. The ship was diverted to Haiti and played a ma- On completing the humanitarian side of the mission, they
jor role in the initial relief efforts. Working in close collabo- changed direction, continued to Curaçao and turned their
ration with non-governmental organizations, the local au- focus to tackling illicit drugs. Within a mere three months,
thorities, the Dutch marines and the Dutch logistics sup- they seized 3,000 kg of cocaine. From the stories the crew
port vessel HNLMS Pelikaan, the crew delivered supplies to are eager to tell, it’s clear that the combination of drug-bust-
places that had been hit worst. ing and aid relief made the last mission exhilarating, per-
PHOTOS: Julius Schrank, Nicky Bakker (3)
“It was really important to do this in a structured sonally rewarding and also very successful.
way, otherwise it would have been just a survival of the fit-
test,” explained Executive Officer David Boom, who is sec- THE CARIBBEAN CORRIDOR
ond in command on the HNLMS Holland. “Our small boats The bulk of work on the HNLMS Holland involves in-
and helicopter were crucial in getting aid to the villagers in tercepting drug couriers passing from the Central Ameri-
the southwest of the island, as the roads were down and the can coastline to the Netherlands Antilles, most commonly
harbors destroyed. The fact that we were so well trained to Curaçao. It’s a route where hundreds of kilos of cocaine
36
NO 02.2017
3
Safe and sound and
back in the hull of the are regularly seized on a single day. What’s missed often
“HNLMS Holland”: Two
makes its way to The Netherlands, usually by air to Amster-
FRISCs accompany
each operation. dam and by container ship or even private yachts to Rotter-
4
dam, the so-called drug gateways of Europe.
The day starts with a The ship has the perfect design, technology and en-
precise check of the
MAN engines.
gines for such low-intensity, rapid-response security oper-
ations. Since the vessel is fitted with state-of-the-art sensor
and communication technology, a Thales Integrated Mast
IM-400 with high-level electronic and radar surveillance ca-
pabilities, the crew is able to detect and track both high- and
low-altitude air targets, as well as sea targets, including the
fast speedboats typically used for trafficking cocaine. They
are usually no match, however, for the speed and agility of
a Fast Raiding Interception and Special Forces Craft (FRISC)
traveling at 45 knots, or the NH-90 helicopter, that both
have their home on board and can take up the high-speed
engines from start to will have no chance of success,” the captain explains. Pow-
a maximum power
ered by two MAN 12V28/33D diesel engines, which have
been specifically designed for navy ships, the HNLMS Hol-
of 1,000 rpm in just land has at its disposal 10% more power than similar en-
a few minutes.”
gines that are fitted in ferries. With up to 1,032 rpm, they
have an output of 6,000 kW. The chief engineer, Sergeant
Major Marco Greene, Chief Platform Systems, highlights
Sergeant Major Marco Greene,
the capabilities that make a difference: “Once at working
Chief Platform Systems, HNLMS Holland
temperature, we can take the engines from start to a
37
NO 02.2017
time diagnostics of the engines,” explains the chief engi- ues and will get tougher and more rigid in the coming
neer Greene. This is enabled by the MAN SaCoSone control months. They need to be prepared for their next deploy-
and monitoring system. Greene has been in the navy for 31 ment to the Caribbean, in February 2018. Whatever that
years, serving on many types of vessels, but much prefers might bring. ▪
38
NO 02.2017
To be in control of
the ship and to get
it to safety, working
with the crew, is
such an awesome
feeling.”
Lieutenant Fraukje Kok,
Navigating Officer
3
A compact vessel: The
“HNLMS Holland” is
108 meters long and
18 meters wide.
4
Safety first: The crew
knows who’s in the
engine room at all
times.
5
A moment of pride for
the whole crew:
Executive Officer David
Boom receiving the
Dutch Navy Medal. 4
39
NO 02.2017
OFFSHORE
TURBINES:
UP AND TURNING
Here’s some good news: There’s
enough wind energy blowing across
the oceans on our planet to power all
of humanity. So say Anna Possner and
Ken Caldeira of Stanford University,
who authored “Geophysical potential
for wind energy over the open oceans,”
published in August 2017. The two aca-
demics are optimistic about the future
of the offshore wind energy industry
internationally, and in Europe specifi-
cally. “Even in the relative calm of
summer, the upper geophysical limit
on sustained wind power in the North
Atlantic alone could be sufficient to
supply all of Europe’s electricity,” they
write. The offshore advantage is obvi-
ous: Wind is weakened on land by ob-
stacles both natural and man-made,
from mountains to skyscrapers, but
the oceans present no such problems.
They do, however, offer challenges that
engineering, technology and logistics
have to deal with.
40
NO 02.2017
▶
First the construction:
Specialist vessel the
“Pacific Orca” handles
this demanding task.
◀
PHOTOS: Paul Langrock/Zenit/laif; maritimephoto.com
41
NO 02.2017
We can move
at very short notice
and need four or five
days to finish a job.”
Stig Holm, Head of On-site Recovery,
MAN PrimeServ Copenhagen
▲
Installed inside for
absolute reliability:
RENK gearboxes
reduce operational
costs.
THE CONVERSION
CHALLENGE:
FROM WIND TO ENERGY
Jurik Kiewit, Branch Manager Wind at RENK, is very
familiar with the offshore world. “The operational
expenditure for offshore turbines is extremely
high. If a gearbox fails onshore, it’s a pain to deal
with, but having to change one out at sea is a real
nightmare. In the industry, it’s really no secret that
over 70% of gearbox failures are due to ordinary
roller bearings. We reduce those failures with our
slider bearing technology, and therefore also reduce
operational costs.” RENK gearboxes were first in-
stalled in offshore wind turbines over 14 years ago
– and they are still running reliably today. “The in-
dustry has only recently recognized that slide bear-
ings provide a more reliable solution, and is now
▲
slowly shifting to this technology,” he adds. “We’re Holding her steady:
the only manufacturer with such a solid track re- Dynamic positioning
and nerves of steel are
cord, with over 200 units successfully installed.” prerequisites for the
challenges at sea.
42
NO 02.2017
◀
A crucial task: Skilled
personnel eliminate
downtime with timely
service and repairs.
When technicians are needed at sea, service vessels take center stage. “For short
distances, smaller Crew Transfer Vessels are used; for longer trips, more special-
ized Wind Service Operation Vessels (WSOVs). These WSOVs are driven by several
GenSets, providing diesel-electric power for more hotel load, crane capacities and
dynamic positioning mode,” says MAN’s Christian Kamm. Crucial for the service
engineers is also a comfortable ride, and a safe and secure transfer. Out in the mid-
dle of the ocean, this requires a vessel capable of precise maneuvering in precar-
ious conditions. Recently, MAN has equipped a newly designed 83-meter WSOV
with variable medium-speed GenSets for Louis Dreyfus Armateurs, the French
shipowner, for wind farms in the North Sea. The engines can be equipped with
PHOTOS: Areva, Jiri Rezac (4)
MAN’s own SCR system to reduce emissions and meet IMO Tier III standard. As
the costs for setting up offshore turbines continue to decrease, and the 2020 dead-
line for achieving the European Union’s target of meeting 20% of its total energy
needs with renewables approaches, such vessels are part of an array of sustainable
solutions that will help meet the challenges of the forces of nature out at sea. ▪
43
No 02.2017
ADDITIVE MANUFACTURING:
THE REAL REVOLUTION?
Disruption, revolution or evolution? How far can additive production processes truly
change manufacturing? What are the realistic expectations of 3-D printing – and who stands
to benefit? MAN Diesel & Turbo spoke to Professor Johannes Henrich Schleifenbaum, the
Head of Additive Manufacturing and Functional Layers at Fraunhofer Institute for Laser Technology
and the Chair for Digital Additive Production at RWTH Aachen University.
Professor Schleifenbaum, you are a bridge think outside of the classic assembly-line to 30 years. We need to do more in schools
between academia, research and industry production methods, such as bonding, join- and universities, but also with seasoned en-
for the breakthrough technology of addi- ing, fusing, milling or other conventional gineers. It’s hard to tell someone to forget ev-
tive manufacturing, commonly known as manufacturing techniques? We need to start erything they’ve learned and been successful
3-D printing. Where do you see its real po- with the requirements for the component, with for years, that they have to start afresh.
tential? The roots to AM lie in rapid proto- and then create a workspace that provides as They need to discover this topic and acquire
typing, which first gave us the opportunity much freedom as possible to design it. This is the necessary new skills and knowhow.
to quickly create a model and grasp it in our the real challenge. It’s not about a direct The fact that this process is not yet tru-
hands, rather than just visualizing it. The transfer of conventional components into ly established is in itself a hurdle. The auto-
power this holds is often greatly underesti- the additive manufacturing processes, as mation technology for AM is not quite there
mated. In my opinion, the true beauty of AM that would only result in making them more yet. So far, we’ve been working on taking tra-
lies in being able to transfer creative design expensive to make. dition processes apart, now we have only just
and ideas into real components rapidly. And made the first steps toward creating suitable
to open up completely new manufacturing How do we change this mindset? Tradition- materials to be used in AM. Most manufac-
possibilities. Instead of having to stick to the al casting and foundry processes have been turing materials were developed for melting
traditional design theories, where we were around for thousands of years. AM just for 20 or milling. For AM, we need materials with
usually advised to stay sym- completely different charac-
metrical, we can create bionic teristics. For instance, we’re
of AM lies in
id exteriors. This is where AM glasses for this technique.
will take us. When we reach Rapid prototyping is at its
components rapidly.”
technology, but in design. als. But this layering, rather
How do we get people to than casting, creates another
lieve we’ll ever be able to print whole cars, even greater role in the design of new prod-
turbines or diesel engines. Conventional pro- Will AM support the industry trend toward ucts, in rapid prototyping and in manufac-
duction methods have a legitimate place in digitalization? We call this seamless produc- turing itself. But the real key to this develop-
manufacturing. But I strongly believe there is tion. Industry 4.0 will be a success when we ment lies with us humans. The ability to
huge potential in AM. And I think we are in digitally incorporate and connect every step think outside the box will become more im-
for some surprises in engineering. on the supply-chain process, from design to portant than ever before. ▪
45
NO 02.2017
◀
Optimized
throughout:
combustion
process,
mechanical
strength and
eco-footprint.
82,000
The number of life-changing surgeries performed since 1978 on board
the hospital vessels of the Mercy Ships charity. MAN Diesel & Turbo is a proud
500,000
The amount of renewable fuel, in metric tons, to be produced
annually at La Mède biorefinery operated by Total, the French energy
company. Facilitated by MAN compression technology, this
world-class plant produces high-quality and renewable biodiesel
sponsor and a long-term partner of this international NGO. from vegetable oils, wastes and residues.
46
NO 02.2017
◀
Whether
offshore or on land:
Comprehensive
service packages
are in demand.
MAN Diesel & Turbo. “Closing the gap in the supply of elec-
tricity on over 900 inhabited islands can only be achieved
by decentralized units. We offer the ideal solution for this.”
With a population of around 255 million, a growth rate of
almost 5% and a growing demand for energy, Indonesia is ▲
Time to light up more
the largest economic area in Southeast Asia and the world’s than just Jakarta:
largest island state. 900 Indonesian islands
want a stable power
supply too.
47
What Makes a Refinery Refined?
Reliability and efficiency are everything.
10,000+
MAN turbomachines are installed
worldwide. That’s more than 50 in
every country in the world 100,000+
continuous working hours of flawless
operation: oil-free screw compressors
250+
from MAN Diesel & Turbo
Compressors Steam Turbines Expanders Machinery Trains Gas Turbines Reactor & Apparatus After Sales
The more the global economy develops, the greater the need for efficiency in supplying the energy sources the world
relies on. With their legendary reliability, MAN Diesel & Turbo machinery and components are used throughout the
refinery and petrochemical industries. Applications range from hydrogen production and recovery to desulfurization,
fluid catalytic cracking (FCC), PTA, fertilizer and IGCC. Engineered to the most exacting standards, our axial, screw
and centrifugal compressors, steam turbines and reactors are built to ensure maximum availability in even the
toughest environments. Find out more at www.mandieselturbo.com