www.zf.com/marine

MarinePropulsionSystems

Edition 1.2015

TRP1_1403103_Karte_85x55.indd 1 19.08.2014 11:09:40

impressreport Marine Propulsion SystemsA customer magazine for business partners of the ZF Marine Group

Published byZF Friedrichshafen AG – Business Unit Marine Propulsion SystemsEhlersstr. 5088046 Friedrichshafen, GERMANyPhone +49 (0)7541 77 7375Fax +49 (0)7541 90 7375www.zf.com/marine

Editor in ChiefSabrina MünchMarketing & Communication

Editorial ResponsibilityMartin MeissnerMarketing & Communication

Cover pictureAres yachts 53 Coupe – one of the many modern designs from this fl exible Turkish shipyard.

Ares Workers assembling a vessel hull.

Daniel Härter Executive VP, Industrial TechnologyBusiness Unit Marine Propulsion Systems

PERSPECTiVES

Foreword

logical offerings to the automotive sector, the cascade of technology or “tech transfer” that will surely come will benefi t not only the marine business unit, but all of the divisions of the ZF Group, and of course, our customers.

But back to the business of Marine – we closed the year 2014  in a good position,  ready  to  jump  into 2015. The ToughGear brand was launched at SMM this past year and continues to grow momentum. Our workboat trans-mission family is truly designed from the very start for the toughest duty cycles, in the most challenging appli-cations. They truly are Tough Gears. You will surely see more about Tough Gear at events and in our promotio-nal activities. Our commercial thruster business remains very  encouraging,  with  the  continued  adoption  of  the technology  in  the  US  inland  river  ways  system.  Fleets continue to be impressed by the improved performance, maneuverability,  and  reduced  fuel  consumption  this technology offers.

This past fall we launched Supershift2 shifting techno-logy. The engineering teams analyzed every piece of the hydraulic  and  mechanical  shifting  components  on  our Friedrichshafen produced transmissions. They have im-proved  and  refi ned  the  complete  system.  The  result  is signifi cantly improved shift performance and improved passenger comfort, without the loss of positive shift en-gagement feel that captains have come to expect from ZF marine transmissions.

2015 will be truly important for the ZF Group, and I am convinced that ZF’s marine business is positioned well to be successful during this benchmark year.

Thanks for your time,

4 News from the Regions

6 Cover Story

Strength through partnership

9 News from the ZF Group

ZF celebrates 100 years

10 Facts and Figures

10 News from the ZF Marine Group

ZF ThrusterCommand® – the next step in thruster control

11 Parts & Service

Expansion in Africa

Let me fi rst say hello and offer up a brief introduction. It’s been about 6 months since I’ve taken the helm at ZF Marine. The time has gone very quickly as I get to know our team here and you, our customers around the world. There is a saying, “it is like trying to take a drink from a fi re hose”, and these fi rst months have proved this say-ing true. Looking forward, to secure the company’s long term growth strategy and success, the Marine Propulsi-on Systems Business Unit is focusing on quality, cost po-sition, customer satisfaction, and continuous innovation. I  have  been  with  ZF  for  a  number  of  years,  and  hope that  my  time  and  experience  within  the  organization will only help build and strengthen our marine business.

2015  is  an  exciting  year  for  the  ZF  Group.  First  it  re-presents  our  centenary.  In  1915,  Zahnradfabrik  Fried-richshafen AG was formally entered into the register as a German company. Count Ferdinand von Zeppelin esta-blished the company to make transmissions for his bur-geoning aircraft business. From that small start, and the following 100 years of  evolution, ZF  is,  today,  a world leader in driveline technology solutions for many custo-mers and a multitude of applications around the world. Marine propulsion  systems has played an  integral  role in ZF’s growth over the years, as it was one of the very early product families developed after the launch of Zep-pelin transmissions.

Second, and of equal importance, we are about to merge with TRW, a US based automotive supplier of an almost equal size to ZF. This combined organization will result in ZF being the second largest automotive supplier in the world with approximately 145,000 employees. While the immediate benefi t will be realized in the added techno-

The “ZF MarInteractive” App from ZF Marine Propul-sion Systems is designed to help those in the industry who need to reference our products on a regular basis, the app features:

Commercial and Fast Craft products with 360° view

Detailed product information

Transmission matching tool (for Pleasure, Commercial,

and Fast Craft applications)

General information about ZF Marine including cont-

acts, exhibitions, and the latest brochures

An Aftersales & Service section includes a contact

form, list of regional competence centers and help line

ZF mAriNe oN Your smArt PhoNe AND tABlet

report Marine Propulsion Systems 1.2015 54

News from the RegionsNews from the Regions

Australian Vessels Take on ZF Transmissions – A trio of Australian vessels have found propulsion solutions with a variety of

ZF Marine transmissions. Ocean Jet, a high-profile jet boat which takes passengers for offshore adventure rides is powered by

a pair of 380hp turbocharged diesel engines, which transfer power to the water jets via a pair of ZF 280-1 transmissions. The

new 14m long aluminium catamaran, Shootingstar, is fitted with a 509hp engine, and ZF 305-2 transmission, which propels

the craft to a maximum speed of 27 knots. Rounding out the trio is the 17m long alloy catamaran Passion, built for a well-

known and internationally respected Australian naval architect. Fitted with a 315hp engine and ZF 63 IV transmission in each

sponson, Passion has been constructed with the highly efficient hull design good for a top speed of 23.5 knots.

AustrAliA

Supershift2 unveiled – At the Fort Lauderdale International

Boat Show this past fall, ZF unveiled the new Supershift2

Shift technology for ZF 2000 series and higher transmissions.

Viking yachts debuted their new 92’ (28m) sportfishing yacht

at the event. It was equipped with MTU power mated to ZF 5050A

transmissions with Supershift2. The development team at Viking praised

the quality of shift performance and feel. They were impressed with how

quickly the gear engagement took place, and the smoothness of engage-

ment. They also appreciated that there was still that positive engagement

feel that they’ve come to expect from ZF transmissions.

ZF Marine Propulsion – getting crews and tools out to wind farms –

Transporting personnel and equipment quickly and safely by boat to offshore

wind farms in all weather requires reliable, efficient equipment. MPI Workboats

Ltd, a leading operator of high performing, purpose-built wind farm support

vessels in the UK, can be assured of such reliability with the ZF 2050, and

2000NR gearboxes installed in six of their latest vessels. MPI’s vessels operate up to

2500 hours per year, carrying up to 10 tons of cargo and personnel. MPI person-

nel are happy with the performance and support they receive from ZF Services

UK to keep their fleet going. MPI is not alone, currently over 170 ZF transmissions

are in service in wind farm support vessels operated in the UK.

Class Certification for W1800 Transmission – In an effort to increase opportunities in the

Asia Pacific region for W1800 transmissions that are built by ZF Marine Sorocaba, a project

was recently initiated to gain Type Approval Certificate for this product. From March through

September 2014 a multi-departmental team came together and undertook activities to

complete the NKK (Nippon Kaiji Kyokai), classification process. The Japanese classification

society NKK is the largest classification society in Asia, with the largest tonnage represen-

ted, and the greatest presence in the region. An NKK surveyor was on site in Sorocaba at

the end of September to verify all facets of the application and the Type Approval Certificate

was issued. The team of ZF employees are very proud, as this represents the first Type Appro-

val for ZF Marine Sorocaba in Brazil.

ZF Marine Equipment Promotion Seminar in Guangzhou – This past December, The ZF

Marine Equipment Promotion Seminar was held in Guangzhou Pazhou, China. The meeting

was arranged during the Guangzhou marine exhibition in order to make it available to more

customers. This gave ZF the opportunity to better convey the ZF product and services mes-

sages regarding thrusters and transmissions. Around 40 customers including shipyards, ship

owners, and design companies were in attendance for the presentation.

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News from the RegionsNews from the Regions

76

STRENGTH THRoUGH PARTNERSHiP

No one can say for certain where man transitioned from building primitive rafts and canoes to the art of crafting ocean-going  vessels.  But the southern coast of Tur-key  is  as  likely  a  spot  as any in  the ancient world. And  today,  a  young  Tur-kish shipyard is drawing upon the rich marine heritage in the region to make its mark in the competitive wor-ld of military and para-military patrol vessels. And, of course, ZF marine propulsion systems are a key compo-nent in its increasingly popular designs.

Ares  Shipyard  began  as  a  shoestring  operation  in  2006 with its workers crafting early designs out in the open air or under plastic tarps. But what the company lacked in re-sources, it more than made up for in drive and ambition.

Located in the Antalya Free Zone, Ares was surroun-ded  by  a  rich  culture  of  leisure  boat  builders  and  marine component suppliers – all in an area that was historically home to fearsome pirates in a bygone age, an irony that would become more apparent over time as the fl edging shipyard gained its sea legs. As the new company  stabilized  and  grew,  its  management  team took decisive steps to ensure a sustained growth track: Milestones  included  achieving  ISO9001  certifi cation and valuable experience gained on early contracts  to build patrol vessels to several navys, coast guards and maritime  enforcement  agencies  throughout  the  regi-on. Small successes followed, and over time, Ares was able to expand its operations to include the constructi-on of commercial ships including a 111-foot crew boat and a series of fast passenger ferries.

This  hard  work,  bolstered  by  persistent  marketing  and promotion efforts by Ares, eventually paid off  in spades. In the past two years alone, the shipyard has won or been awarded signifi cant domestic and international contracts, often edging out larger and more high-profi le competitors. A large part of this steady, sustained growth can be attri-buted  to  the  company’s  “Strength  Through  Partnership” philosophy, which calls for seeking out, and working clo-sely with a select few designers and equipment suppliers in the marine industry. This approach has proven fruitful for Ares: The last three contracts awarded to the company were a collaboration between Ares and BMT Nigel Gee, a noted independent naval architecture and marine enginee-ring design consultancy fi rm equipped with the experien-ce, personnel and resources to deliver high quality ship de-sign, resulting in vessels that are timeless, original and fully 

Cover StoryCover Story

report Marine Propulsion Systems 1.2015

functional to the needs and requirements of each client.Today, Ares continues to grow and take on new challen-

ges. The shipyard recently won  a  contract  to  build 17  new  vessels  for  Qatar’s Coast  Guard  Service  in one of  the  largest  known 

single composite contracts for vessels ever awarded by the  country. 

The Qatar contract specifi es delivery of three different types of vessels from Ares, consisting of fi ve 75-foot pa-trol  boats,  ten  108-foot  patrol  boats  and  two  105-foot patrol boats. All of the vessels will be outfi tted with the same  components  from  the  same  group  of  suppliers: the engines will be supplied by MTU and mated with ZF gearboxes. 

Due to design requirements, each vessel type will feature slightly different confi gurations. But the overall goal will be to ensure redundancy in operation and commonality of spares and equipment for maintenance and service.

In addition  to  the Qatar  contract, Ares  recently beat out several  larger,  well-established  domestic  shipyards  when the Turkish government recently awarded Ares a contract to build two Special Forces fast boats for the Turkish Navy.

PARTNERSHiPA young Turkish shipyard makes its mark

in the modern marine world.

ZF marine propulsion systems are a key component in Ares Shipyards popular designs.

Special Forces fast boats for Turkish Navy.

Ares vessels range from patrol boats

to luxury commercial ferries

report Marine Propulsion Systems 1.2015 98

Cover StoryCover Story

Challenging designs, quality components

As its business grows, Ares remains committed to using carefully selected materials, equipment and component suppliers  from  around  the  globe  with  an  eye  toward eventually laying keels on several designs up to 295 feet in length. The companies Ares chooses to ally with are selected principally to enhance performance, increase reliability and augment the overall function of a design proposal with an emphasis placed on the supplier’s abi-lity  to provide  training,  support  and aftersales  service, quickly, with ease, on a global scale.

In  keeping  with  this  philosophy,  Ares  seeks  out  part-ners with only  the most reputable and proven quality equipment,  machinery  and  systems  suppliers.  Its  pre-ference for engines  is MTU, due to Ares’ belief  in the quality of design and build of  these dedicated marine power plants and the excellent aftersales the company offers.The shipyard’s recent addition of Kamewa water jets to the Ares powertrain team has only enhanced the shipyard’s burgeoning reputation in the region.

In  the  crucial  link  coupling  engine  and  the  propulsi-on  system,  ZF  has  always  been,  and  will  continue  to be, Ares’ preferred suppliers of choice for specialized, high-performance marine gearboxes. Designed  for  ap-plications  in all  types of fast marine craft, Ares desig-ners feel ZF gearboxes are particularly well suited for 

arduous patrol boat applications, especially when cou-pled with water-jets.

The  company’s  preference  and  reliance  on  ZF  Marine gearboxes was solidifi ed in 2013 when Ares was in the process of supplying 10 fast patrol boats to the Turkish Coast  Guard,  as  a  fi rst  tier  supplier  to  Dearsan  Shipy-ard, which was the successful bidding company on the project. The published specifi cation was particularly de-manding,  requiring “big ship” style propulsion systems inside a relatively small boat design. As a result, the de-sign and installation work required high levels of quali-ty  and  engineering  and  function  with  uncompromised performance at sea. Additional requirements included a full chemical treatment plant (without holding tanks) for waste water disposal.  In essence,  the design mandated piping systems, seating, and other facilities more compli-ant with large ships – all for a crew of up to 12 persons.

In  pure  engineering  terms  however,  the  most  challen-ging aspect of  this design was  the combination of a  li-mited 3 foot maximum draft and a minimum top speed of  35  knots  with  conventional  fi xed  pitch  propellers, according  to classifi cation of High Speed Craft  (Naval) rules. An additional complication was the Turkish Coast  Guard’s  insistence  on  aluminum  instead  of  glass-rein-forced plastic (GRP).

Patrol boats with high-performance ZF Marine transmissions

News from the ZF Group

In  September  1915,  "Zahnradfabrik  GmbH"  appeared for  the  fi rst  time  in  a  trade  register.  2015  marks  the 100th  anniversary  of  the  foundation  of  the  ZF  Group The company, started originally by Count von Zeppelin to provide  transmissions  for his  airships,  soon  started to diversify production to supply transmissions for cars and trucks. Not too many years later, in 1935, ZF’s ma-rine propulsion business started when a version of the Zeppelin gearbox was marinized for use behind 1650hp 

Daimler-Benz motors for high speed vessel applications. Today,  the ZF Group  is  a world  leader  in motion and mobility technology for many industries. As well, there is  reason  to  be  optimistic  about  the  future.  ZF  is  cur-rently  undergoing  the  largest  acquisition  in  the  com-pany's history with  the purchase of  the US fi rm TRW Automotive. With the completion of this acquisition ZF will move into a top 3 position in the global automotive supplier industry.

ZF celeBrAtes 100 YeArs!

Throughout  the development, design and build of  these highly  specialized  patrol  vessels,  Ares  relied  heavily  on engineering  support  from  ZF,  most  notably  in  changing the  gearbox  ratios  following  initial  sea  trials,  and  even altering  the  gearing  to  change  the  direction  of  rotation for the fi nal drive – a level of support the company says is not readily available from every supplier in the marine industry. Today, Ares Shipyard continues to use ZF as its primary  gearbox  supplier.  In  fact,  ZF  gearboxes  can  be found  in Ares vessels  ranging  from patrol boats deliver-ed  to  the  Bahrain  Coast  Guard  to  luxury  commercial ferries  for  the Anantara Spa and  Island Resort  in Doha, Qatar. The ZF partnership  is  a  shining  example of how Ares’  “Strength  through  Partnership”  approach  to  ship-building  produces  a  superior,  highly  integrated  vessel. Expanding  upon  this  design  philosophy,  the  shipyard  is now working on a number of national and international projects  and  programs  that  will  ultimately  deliver  new generations of unique ships and offshore boats, designed with uncompromising performance and customer satisfac-tion – before, during and after the sale – utmost in mind.

ZF celeBrAtesits ANNiVersArY!

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ALGERIA

EGyPT

ZF SERViCES MIDDLE EAST

TANZANIA

SOUTh AFRICA

ZF SERViCES SOUTh AFRICA

CO2

88 Million

14 DAYS

report Marine Propulsion Systems 1.201510 11

Facts and Figures

News from the ZF Marine Group

ThrusterCommand® is the latest in complete vessel control. These new cont-

rol systems are supplied by ZF with every 360° steer able azimuth  thruster  and  are  designed  to  control  a  single  thruster, providing steering and throttle control, as well as independent backup and emergency stop functiona-lity. The ThrusterCommand® control system is also avai-lable for tunnel thrusters from ZF Krimpen. 

The  basic  setup  of  the  control  system  consists  of  a  Thruster Control Unit (TCU), which is positioned in the thruster room, in the immediate vicinity of the thruster, and a remote panel on the bridge. The TCU is the heart of the system.Optionally a number of additional remo-te panels can be connected (both interior and exterior) which can even be equipped with sophisticated options such as a "electrical shaft", where the control levers of all the panels will move synchro nously with the panel 

that is in control. The ThrusterCommand® system is, of course, also capable of interfacing with all of the equip-ment on  the bridge of  a modern vessel,  such as Auto  Pilots,  DP  systems,  Voyage  Data  Recorders,  external alarm and monitoring  systems and so on, making  it  a truly integrated thruster control solution.

Some of the advantages of the new ThrusterCommand® include:

Better interfacing with external vessel

maneuvering and monitoring systems

Multi language

Compact panels

Fewer wires and cabling needed

Easier to install and configure

Easy to handle

high level of redundancy

ZF thrustercommand® – the Next geNerAtioN iN thruster coNtrol

ExPANSioN iN AFRiCA

Parts & Service

One of the strategic initiatives of ZF Marine is to be the benchmark in marine after sales & service. An important aspect of this initiative is of course the global after sales & service network. For this reason ZF Marine is improving its footprint in Africa for the benefit of its customers.

“When you go fishing, your net must be large enough, dense enough, strong enough and well-connected. The same principles apply to our service network as well” says Martin Hagenacker, Manager of ZF Marine Propulsi-on Systems’ After Sales & Service Network. “We are well represented in most of the busiest marine centers world-wide and now it´s time to improve further on in Africa. We want to improve the availability of parts and qualified technical support on the entire continent”.

While  ZF’s  competitors  may  work  with  “flying  doctors” for this area, ZF sees the demand to offer  local support in key regions. Customers are already acting globally and expect the same from ZF. With local partners we reduce the reaction time drastically, as there is no need to apply for travel visas or long journies to get on site. Also, due to 

their experience they also know how to ensure rapid part supply. With this initiative ZF ensures to keep pace with the economic development of African countries and the increasing demand for local service in the marine sector. 

The first important step will be to enlarge ZF’s footprint and  establish  5  local  after  sales  &  service  competence centers  in addition  to  the existing subsidiaries  in South Africa.  The  first  target  locations  are  Morocco,  Algeria, Egypt, Tanzania and Ghana. Partner companies have al-ready been selected. Once demand and business increa-ses, further expansion will be evaluated, but right now the focus is to ensure that new partners are well qualified to offer top quality service.

Even though these partner companies are already famili-ar with transmissions and marine products, the full capa-bilities and skills cannot be acquired overnight. ZF has set up “sales and service readiness projects” for each of them but for sure our Product Competence Centers in Europe will back-up our new partners until they are qualified to take on the business.

…american adults still participated in boating last year, althought boating participation has slipped

in general.

Females constitute only about 2% of seafarers.

Container ship travels the equivalent of three-quar-ters of the way to the moon and back in one year

during its regular travel across the oceans.

China has over 20 yards that can build yachts above 24m (78ft).

The entire container voyage from China to Europe is equal in CO2 emissions to about 200 kilometers

of long-haul trucking in Europe.*

*whitepaper released for the Transport Intelligence Europe Conference

… is the usual age of retirement from "active service" for sea containers and reefers.

The cost to transport a bicycle from Thailand to the UK in a container is about US$10. The typical cost for shipping a DVD/CD player from Asia to Europe or the U.S. is roughly US$1.50; a kilogram of coffee

just fifteen cents, and a can of beer – a penny.

One-Third of all ship crews worldwide are people from the Philippines, with nearly

a quarter million at sea.

Offshore jobs can be extremely challenging and may demand long working hours in harsh

conditions. Crews generally work offshore for 14 days followed by a 14 day rest period onshore.

The ToughGear® Series of transmissions from ZF Marine Propulsion Systems are built to handle the toughest and most diverse of tugboat and offshore workboat duty cycles – by offering the durability, reliabilty, safety, versatility and ease of maintenance that you‘ve come to expect from ZF. www.zf.com/marine

ZF iS PRoPULSioN.