Zero Pollution Solutionsfor Age Old Problems

A Return to Seawater Lubricated

Propeller Shaft Bearings

January 5, 2015

Overview• Introduction to Thordon Bearings• Non-Polluting Bearings Rudder Bearings Stern Roller Bearings Deck Equipment Bushings

• Sea Water Lubricated Propeller Shaft Bearings

System Components Conversions Commercial Ship References

• Ship Owner Benefits2

Thordon Bearings Inc.

• Head office: Burlington, Canada• State-of-the-Art polymer processing facilities Main production plant in Burlington, Canada Additional plant in Poland

• In-house design, CAD and R&D facilities• Currently ISO 9001:2008 certified• Extensive distribution network Over 85 distributors Over 100 countries served

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‘Green’ Technology• World leader in elastomeric bearing

technology for over 35 years Non-metallic, self lubricating journal bearings Proprietary polymers

• Pollution free replacement for grease or oil lubricated metallic bearings With equal or better operating performance

• Proven technology in service around the world

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Thordon Bearings Inc.

ThorPlas-Blue Grease Free Deck Equipment Bearings

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Eliminate grease and labour cost with ThorPlas-Bluebearings

ThorPlas-Blue• Best for problem areas that have Frequent maintenance Grease lubrication not always possible High cost consequence of seized bushings

• ThorPlas-Blue eliminates grease Labour time and cost Potential pollution source Eliminates safety issues of manual greasing

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ThorPlas-Blue Applications• Lifeboat and tender davits and sheave

bushings• Fairleads• Cargo ramp bushings• Ride control equipment• Winches• Hinge points on doors and hatches• Cranes hoists and deck loading

equipment• Pumps

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Stern Roller Applications

• Thordon SXL stern roller bearings on the aft end of offshore support vessels

• Stern roller thrust washers

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Grease Free Rudder BearingsOver 4,000 rudder bearings installed globally

SXL Rudder Bearing Benefits• Tolerates misalignment better than rigid

plastics or bronze• Dry or water lubrication eliminates

greasing systems; zero pollution risk• High abrasion resistance

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Oil Lubricated Propeller ShaftsShaft and Pod Seals are not perfect• Pollution risk

Seal must leak to lubricate its sealing lip Oil pollution from leaking shaft or pod seal Escalating detection and enforcement

• MARPOL Annex I / Satellite tracking• Criminal fines / jail terms

Increased expectation of corporate responsibility

• Damage to corporate brand and image

• Catastrophic failure risk Major loss of stern tube oil Vessel may be stranded at sea Significant seal and pod repair cost

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Operational Oil Leakage

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Environmental Research Consulting study “Total annual inputs of lubricating oil worldwide from stern tube leakage and other operational discharges into port waters is estimated to be between 37 million to nearly 61 million litres. If the same rates of discharge occur at sea as they do in port, the estimated worldwide annual inputs of lubricants to marine waters both in ports and harbours and at sea might be estimated to be about four times the port estimate. This assumes that each vessel spends, on average, three days at sea for every day in port. Total worldwide use of lubricants from operational leaks and discharges would then be about 130 million to 244 million litresannually.

Etkin, Dagmar Schmidt. Environmental Research Consulting “Worldwide Analysis of In-Port Vessel Operational Lubricant ,” Arctic and Marine Oilspill Program Technical Seminar of Environment Canada, 8 June 2010, Halifax, Canada

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Accidental Oil Leakage

• Typical causes of increased oil leakage from stern tube seal damage: Fishing nets or rope caught in the propeller Propeller shaft misalignment or bent shafts Aged or worn lip seals Propeller contact

with ice or ocean floor

Accidental Oil Leakage

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Rope and fishing line damage aft seals.

Lloyd’s Register reports: “aft stern seal and forward stern seal represent 43% and 24% of failures respectively.”

3 Smith, Andrew, Lloyd’s Register Global Technology Leader-Engineering Systems .,

“Shaft Alignment Problems Analyzed,” Marine Engineers Review April 2009, pp. 16

EAL’s – Still considered a pollutant (less harmful than mineral oil)

Oil-based EAL’s are still considered a pollutant under the Oil Pollution Act of 1990 (OPA ‘90) and US Clean Water Act (if there is a sheen)

Any discharges of oil-based EAL’s still require reporting of the discharge to the U.S. Coast Guard, as well as having clean-up and remediation costs.

Even though biodegradable lubricants may be deemed non-toxic by OECD testing, their presence on the water surface is a threat to seabirds

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Shaft Air SealsAre they the answer?

• A major seal manufacturer states the following related to air seals on their website:

However, since it is not possible to rule out circumstances in which there could be a leakage, EALs must be used on this type of seal as well.

• Depending on seal manufacturer and EAL, the EAL will need to be replaced either at 2.5 or 5 year drydocking (aggressive nature of the EAL on seals)

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http://www.simplexturbulo.com/2013/07/12/vessel-general-permit-latest-news/

Typical Piping of Air Seal

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Air control unit Air source(Control Air)

L.O. tank unit

Floatswitch

Stern tube

Stern tubeL.O. pump unit

Filter

Pump

Draincollection unit

Flow meter

AirOil

Slight amount of airis leaked from here.

Aft seal

Cooler

Needle valve

Seawater Lubricated Propeller Shaft Bearings

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Over 2,000 vessels with Thordonpropeller shaft bearings installed

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Water Lubrication• Seawater as a lubricant dates back to

earliest days of shaft driven propellers• Thordon COMPAC - No grooves on

bottom half to induce hydrodynamic film formation at low shaft speeds

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Video

• Open Water System Components

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COMPAC BEARINGSFWD Seal

Sea Water from Water Quality PackageShaft Liners

Shaft CoatingOr Cladding

Water Flow

System Components

NO AFT SEAL!

Piping for Seawater Lubricated Propeller Shaft Bearing System

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NO AFT SEAL!

COMPAC Bearings• Elastomeric polymer alloy bearings• Best combination of strength/stiffness and

flexibility/elasticity toughness abrasion resistance shock loading

• Thordon is homogeneous Typical bearing wall thickness

of 20-25mm (0.787” -0.984”) • Typically, 2:1 L/D ratio for AFT bearing and

1:1 L/D ratio for FWD position23

Thordon COMPAC Bearings• Class approved design for pressures to

0.6MPa (87 psi)• Fitted in bronze carrier or installed directly

into stern tube

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Split COMPAC Bearing with Single Tapered Keyset

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Split COMPAC -Single Tapered Keyset allows for easy removal, inspection and re-install in a matter of hours without shaft withdrawal (left: COMPAC bearing inspection on Disney Magic at Norshipco, December 2000)

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Thordon Water Quality Package• Designed to provide a clean supply of

water to our water lubricated bearings Controlled environment

• Flow is monitored and low flow alarms provided Removes abrasives Improves bearing wear life Self contained unit Several configurations available

Controlling the Bearing Environment-Thordon Water Quality Package

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Video

Shaft Coating• Class approved shaft coating or non-

corrosive material required• Thordon has developed Thor-Coat A highly flexible, tough corrosion

protection coating for propeller shafts designed to extend shaft withdrawal period

ABS, LRS, GL, BV, NKK approval; DNV is case-by-case; RINA approval not required

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Thor-Coat

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Shaft Liners

• For COMPAC bearings, typical shaft liner materials will be: Gunmetal, (typically CuSn10Zn) 70/30 copper nickel Inconel® 625

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Sealing Arrangements Only Forward Seal is Required Lip seal Face seal Stuffing box

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Disney Magic equipped with COMPAC since 1998

Long Predictable Bearing Wear Life

Two ships (83,000 GT) built at Fincantieri (Italy) -1998/1999 and two more at Meyer Werft (Germany) -

2011/2012. All equipped with COMPAC seawater lubricated propeller shaft bearings.

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Carnival Corp. (U.S.A.) – 13 Cruise ships (108,000 to 115,000grt) equipped with COMPAC. Three more on order.

Grand Princess equipped with COMPAC since 1998

Long Predictable Bearing Wear Life

Vessels Converted from Oil

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Converting to COMPAC

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Conversion OverviewStart planning early !

Tie conversion into a scheduled docking (tailshaft survey cycle)

Conduct engineering up front to minimize unanticipated problems

Utilize standard designs where possible Seal(s) and metal work (liners) can have long

lead times

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Conversion References:Oil to Water

• Algoma Corp. (Canada) 2010-2013: 5 bulkers

• ConoccoPhillips (U.S.A.) 2010-2012: 5 oil tankers (141,739 dwt)

• Fraser River Pile & Dredge (Canada) 2011- Fraser Titan (triple screw dredger)

• Seacor (U.S.A.) 2013 – EOT Spar (3,095 dwt dry cargo ship)

• 4 other conversions (3 bulkers, 1 Coast Guard buoy tender)

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Proven Technology!

Over 600 commercial ships equipped with COMPAC seawater

lubricated propeller shaft bearings, including…

Who Uses Seawater Lubricated Propeller Shaft Bearings?

Over 600 commercial ships including…• US Gypsum Corporation (U.S.A.) – 2 bulk carriers• Carisbrooke Shipping (U.K.) - 8 dry cargo ships• CSL (Canada) - 9 bulk carriers • COSCO (China) - 12 bulk carriers, 3 car carriers, 2 on order• BC Ferries (Canada) - 10 ferries• Staten Island Ferries (U.S.A) - 3 ferries• Tidewater (U.S.A.) – 5 AHTS vessels• ConocoPhillips (U.S.A.)- 5 oil tankers • Disney Cruise Lines (U.S.A.) – 4 cruise ships

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COMPAC Guarantee15-Year Bearing Wear Life Guarantee• Commercial newbuild ship owners of ships with stern tube

(single/twin screw) with shaft diameter of 300mm (12”) or greater

• Ship owner must clearly specify the complete COMPAC system to the shipyard in order to qualify for the 15-year wear life guarantee.

• We can offer this guarantee because of our confidence in Thordon COMPAC propeller shaft bearings and the proven experience and wear life of COMPAC bearings operating in commercial vessels in the last 25 years

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Technical Equivalence to Oil Lubricated Propeller Shaft Bearings

• New Lloyd’s Register rules for Water Lubricated Propeller Shaft Bearings

• SCM (Screwshaft Conditioning Monitoring) Notation For water lubricated propeller shaft bearings Effective Jan. 2013

• If vessel is compliant, no shaft withdrawal until 18 years from newbuild

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Trading in US Waters?• 2013 Vessel General Permit (VGP) regulates

discharges from commercial vessels in ‘US waters’ effective Dec. 19, 2013

• Section 2.2.9: All vessels must use an EAL “Environmentally acceptable lubricant” in all oil to sea interfaces, unless technically infeasible

• EPA recommends that all new build vessel operators endeavor to use seawater-based systems for their stern tube lubrication to eliminate the discharge of oil from these interfaces to the aquatic environment.

42 http://www.epa.gov/npdes/vessels

Lower Life Cycle Costs

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Newbuild Aframax tanker (640mm shaft diameter) 25 year vessel life

Note: This system estimate is for budget purposes only. For a true quotation, please contact Thordon Bearings Inc.

Life Cycle Cost AnalysisSeawater Lubricated COMPAC

Propeller Shaft Bearing SystemOil Lubricated White Metal Prop Shaft Bearing System

Bearings and Related Shaft Line Equipment $189,950 $193,500Shaft Liners $66,500

Cost of Acquisition & Installation $256,450 $193,500

Cost of Ownership (25 Years) $134,000 $535,840

TOTAL $390,450 $729,340

Ship Owner Benefits• Zero Pollution Risk Eliminate oil from the stern tube

• Controlled Bearing Environment Thordon Water Quality Package Allows for SCM Notation (LR) – No shaft

withdrawal for 18 years with monitoring• Survivability Non catastrophic failure mode allows

vessel to get back to port

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Ship Owner Benefits• Long predictable bearing wear life Fifteen year bearing wear life guarantee

for newbuilds Installed on over 600 commercial vessels

to date• No Emergency Dockings

• No emergency seal repairs ($$$) - no risk of rope/line damage to AFT seal

• Predictable wear life/no oil leakage

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Ship Owner Benefits• Reduced Operating Costs

• No Aft seal to maintain as there is no Aft seal (water lubricated FWD seal only)

• Eliminate oil or EAL’s from the stern tube no purchase of oil or EAL’s no storage of oil no sampling of oil no disposal of oil no labour required to top up header tanks

• Maintenance of seawater lubricated bearing system is very low

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Gaining an Eco-AdvantageFuture Compliance Guaranteed

with Thordon COMPAC Seawater Lubricated Propeller Shaft Bearings

Thank You!