Peter Brotherhood Ltd

Marine Steam

Turbines

solutionsWorld Class Engineering

Waste Heat Recovery Turbo-Generators

Peter Brotherhood's range of marine steam turbines forauxiliary power generation is designed and built to the highest engineeringstandards at the company's manufacturing plant in Peterborough, UnitedKingdom. This plant was purpose-built for the manufacture of the company’sproducts and became fully operational in the latter part of 1994.

The Peter Brotherhood name has a long and distinguished association withships and shipbuilding. The company was supplying steam engines forwarships of the British Royal Navy over a century ago and has beendesigning and manufacturing steam turbines since 1907.Today Peter Brotherhood can justifiably claim to be an integral part of themodern marine industry.

Experience in supplying a large number of steam turbines for Royal Navyvessels during the 1940s and 1950s won the company widespreadrecognition as a major marine turbine manufacturer.

In the late 1950s the number of vessels with steam turbine main enginesbegan to diminish as diesel power became more common. Responding tothe changing market, Peter Brotherhood concentrated its expertise onturbines for on-board auxiliary power generation.

In conjunction with a major tanker operator, Peter Brotherhood designedand developed a steam turbo-generator system that used waste heat fromthe main engine exhaust to produce the steam required for on-boardelectricity generation. As a result, the company quickly established itself asthe leading supplier of turbine-based waste heat recovery systems. To datePeter Brotherhood have supplied over 250 machines with a total capacity inexcess of 300 MW for this type of application.

The same expertise in marine turbine technology has allowed Peter Brotherhood to meet the demands of a variety of other applications,for example turbo-generators for electricity generation on floatingproduction storage and offloading (FPSO) vessels.

The basic concept of a wasteheat recovery system that includes a steam turbo-generator set, is toproduce additional electrical power from the heat energy in the exhaust gasof the main engine. Turning this concept into reliable, economic and efficientengineering products requires a blend of technical and practical expertisethat comes only with experience.

Successful system design depends on variables such as engine power, theproportion of the ship's life spent at sea, and of course, electrical powerdemands. Careful assessment of these factors, together with previousoperating experience and crewing considerations, will give rise to differentdesigns for different applications.

The initial cost of a waste heat recovery based turbo-generator system isnormally higher than that of an auxiliary diesel-powered generator. However,the absence of fuel costs and the lower maintenance requirements of a turbine-based system give rapid capital payback from the higher investment.

Peter Brotherhood engineers possess an unrivalled wealth of experiencewith which to assist ship builders and ship owners in the design of wasteheat recovery systems appropriate to their needs.

Peter Brotherhood turbines have beeninstalled in ships built around the world

Peter Brotherhood has supplied waste heatrecovery turbines for Maersk Sealand

Marine Steam Turbine Design

Peter Brotherhood’s reputation for qualityengineering is enhanced by a continuing commitment to quality assurance.

Conformance with the stringent quality assurance standard ISO 9001:2000 not only guarantees consistently high qualityproduction but also covers areas such as design, purchasing,supplier quality assurance, manufacturing, documentation andbusiness systems.

Impact on the environment is minimised through an environmentalmanagement system approved to ISO 14001:2004.

Peter Brotherhood has extensive experience in meeting the fullrequirements of all relevant marine standards. An appropriateclassification authority, such as Lloyds, ABS or DNV, certifies each marine steam turbine.

3.5 MW marine steam turbinesupplied to a Danish shipyard

550 kW turbo-generator set supplied to a European shipyard

6,000 TEU Container ship that has aPeter Brotherhood auxiliary steamturbo-generator set on board

Each Peter Brotherhood marine turbineis individually designed for its particular application to ensurehighest possible system/cycle efficiency. It is tailored to meetprecisely the required specification but is assembled in modularform from standard, service proven components. This approachallows Peter Brotherhood to manufacture components for stock,providing shorter delivery times and consequently lower costs,without reducing turbine efficiency, quality or design flexibility.

The turbo-generator unit is usually designed as a single packageincorporating the oil tank and all auxiliary components andinterconnecting pipework. This reduces installation time andcomplexity and allows the complete package to be assembled andtested at the factory prior to despatch.

A comprehensive range of Peter Brotherhood turbo-generators isproduced to match all types of systems and ship installations.Single or mixed-pressure turbines are available with an integralcondenser or with connections for exhausting steam to a separatecondenser to suit specific layout requirements.

This ability to match existing equipment layouts makes Peter Brotherhood steam turbines ideally suited to 'retro fit'applications, where waste heat recovery systems may be installedin ships that were originally built without them.

Quality & Certification

One of twelve 6 MW turbine packagessupplied to a Danish shipyard

marine turApplication of Technology

Leading the way in Fuel Efficiency

The introduction of more efficient, long stroke, slowspeed diesel engines for marine propulsion in response to the oil crises of the1970s and early 1980s has meant a reduction in the amount of waste heat thatcan be used for electricity generation.

This has come at a time when on-board electricity demands at sea have beenrising, particularly in cases where the growing requirement for refrigeration oncontainer vessels is a factor.

Peter Brotherhood has responded to the challenge by developing innovativetechnical solutions in co-operation with ship owners and shipyards toovercome the problems of cost-effective on board power generation.

In addition the prospect of possible legislation and local rules with respect tostack emissions from ships has resulted in some cases where valuable cargospace has been taken up by extra fuel tanks for low sulphur fuels. A viablealternative to this in payback terms would be a steam turbine generator basedwaste heat recovery system. Peter Brotherhood has been co-operating withleading shipping lines and shipyards to develop such systems for many years.Some examples of these are illustrated in the following sections.

Peter Brotherhood has supplied a numberof waste heat recovery based power systems to the Gdansk shipyard inPoland. Built for Polish Ocean Lines, each system comprises a waste heatboiler, a steam turbine with associated generator and DC electric motor, agenerator mounted on a shaft from the main engine and associated control equipment.

The boiler produces steam using the heat from the exhaust gas of the mainengine; the steam is fed into the Peter Brotherhood turbine that in turn drivesthe generator. A DC motor, coupled to the other end of the generator, makesup the shortfall when the ship's electrical power demands exceed the steamturbine's maximum output. The electric motor receives its power from thegenerator on the propeller shaft. (See Figure 1)

The total generating capacity of the system is 1.0 MW with peak output fromthe Peter Brotherhood steam turbine being 800 kW - under normal cruisingconditions the turbine delivers 680 kW.

One of the turbo-generator sets supplied to Polish Ocean Lines

Figure 1. A schematic diagram of the Polish Ocean Lines system

Steam turbine

Reductiongearbox

AC generator

DC motor

Shaft generator

Exhaustgas

Exhaust gas flowSteam/condensate flowElectrical power flow

Transformer/rectifier

Power management system

Condenser

Waste heat recovery boiler

rbinesEnergy Saving Systems A novel energy-saving system

aboard a series of 12 partially refrigeratedcontainer ships of the Maersk shipping line usesenergy from the exhaust gas of each ship's maindiesel engine to provide on-board electrical powerand when available, additional power to thepropeller shaft.

Each system includes a waste heat recovery boiler,a Peter Brotherhood steam turbine, two powerturbines, two gearboxes, a generator and an ACgenerator/motor on the propeller shaft.(See Figure 2)

The Peter Brotherhood turbine is capable ofdelivering up to 60 per cent of the generator'smaximum power output of 4.0 MW. Additionalpower comes from the two power turbines thatare connected to the other end of the generatorby a twin-input gearbox. The power turbinesextract energy from the main engine exhaustbefore it enters the waste heat boiler and candeliver more than 1.0 MW to the generator shaft.The package is arranged such that one or both ofthese power turbines can be operated undercontrol of the energy management system in orderto match the ship’s auxiliary electrical powerdemand.

The boiler uses the exhaust gases leaving thepower turbines and those that have passed throughthe main engine turbochargers to generate steam.The boiler supplies this steam at two differentpressures to the multi-stage mixed pressure steam turbine.

The generator/motor on the main engine shaft isused either to supply additional electrical powerwhen demand is high or - in motor mode - ispowered by surplus electricity when electricaldemand is low.

The advanced electronic energy managementsystem controls automatic switching betweendifferent modes of operation and ensures efficientoperation of the equipment under any conditions.

A further development of the above system isillustrated in Figure 3. Here a single higher ratingpower turbine provides power through a gearboxto the steam turbine shaft (rather that the other endof the generator as in Figure 2). This means that theheat and power are at the same end of the packageand a standard generator can be used. In addition,the latest blading technology is utilised to maximisethe exhaust vacuum as is required to produce thehigher powers (6 to 8 MW) associated with evenlarger containerships.

A specifically designed and optimised steam turbinebased waste heat recovery system can producefuel savings in excess of 10 %. This figure can befurther improved when using the higher powersystems associated with large containerships.

Dual pressure turbo-compound package showing the two power turbines

Waste heat recovery boiler

Energy management system

Exhaust gas flowSteam/condensate flowElectrical power flow

Shaft generator/motor

Main engine

Turbochargers

Steam turbine

Reduction gearbox

AC generator

Combination reduction gearbox Power

turbine

Power turbine

Condenser

Figure 2. Dual pressure compound system

Figure 3. Further development of the dual pressure compound system

Waste heat recovery boiler

Energy management system Exhaust gas flowSteam/condensate flowElectrical power flow

Shaft generator/motor

Main engine

Turbochargers

Steam turbine

Reduction gearbox

AC generator

Condenser

Power turbine

marine turTurbo-Generator Sets for FPSO Vessels Peter Brotherhood has

considerable experience in supplying turbo-generator sets to floatingproduction storage and offloading (FPSO) vessels having supplied units tomany of the world’s leading FPSO operators including Woodside, Single BuoyMoorings (SBM), Bergesen, Saipem and Bluewater.

As well as complying fully with all the relevant marine classification societyrules, Peter Brotherhood can also incorporate individual companyrequirements such as API and ASME standards, hazardous area compliance andextensive instrumentation and monitoring.

Turbo-generator sets can be designed to exhaust to the ship’s existingcondensers; alternatively Peter Brotherhood can supply the condenser.For power outputs up to 6 MW, the condenser can be incorporated in theturbine bedplate if required.

4.5 MW turbo-generator set exhausting to anintegral condenser supplied to Vanguard for theWoollybutt project

Two 12 MW condensing turbo-generator sets supplied toSBM for their FPSO vessel in theMarlim Sul Field

An FPSO vessel moored offNigeria powered by a 7 MW Peter Brotherhood steam turbine

One of two 24 MW steam turbines supplied to Bergesen for an FPSO vessel moored off the coast of Mauritania

rbinesSteam Turbine Testing

Engineering Services

All steam turbines manufactured by Peter Brotherhood aresubjected to a rigorous functional test in our Works before despatch. Each setis run on steam at full speed, no load and wherever possible at full operationaltemperature. The testing of the set, with its control panels, ensures that allmonitoring and safety systems are proved to function correctly.

The set is then dismantled and all components checked before reassembly and preparation for despatch and delivery. In this way, Peter Brotherhoodminimises the scope and amount of work required to install and commissionthe set on-board ship.

Peter Brotherhood’s service department offers a uniquecombination of the experience and expertise of an original equipmentmanufacturer coupled with the responsiveness of a service organisation.

Engineering capabilities and products include:

● Steam turbine spares● Re-engineered spares● Plant repairs & overhauls● Installation & commissioning● Plant upgrades & maintenance● Turbine blades & rotor repairs

Bluewater’s Uisge Gorm FPSO supplied with one 1.5 MW Peter Brotherhood turbo-generator set

Peter Brotherhood test bed

Turbine rotor & blades

Peter Brotherhood Ltd

Brotherhood Process & Energy

Werrington ParkwayPeterborough PE4 5HGUnited Kingdom

Telephone: +44 (0)1733 292200Fax: +44 (0)1733 292300E-mail: sales@peterbrotherhood.co.ukWebsite: www.peterbrotherhood.co.uk

MST 02/06

Specialists in the design, manufacture, installationand commissioning of equipment to meet theneeds of the process and energy industries.

The company has considerable experience insupplying steam turbine systems for marineapplications as well as for combined cycle,cogeneration, energy from waste, districtheating, sugar mills, heat recovery and industrialprocesses.

Peter Brotherhood combines traditionalengineering skills with the latest techniques andequipment and has been providing engineeredsolutions around the world since 1867.

In addition to steam turbines, the company alsospecialises in the design and manufacture ofreciprocating gas compressors, CHP systems,special purpose machinery and gearboxes.

In all its activities, from design tocommissioning, Peter Brotherhood works toISO 9001:2000 quality assurance standard and ISO 14001:2004 environmentalmanagement standard.

75% Recycled Paper

Brotherhood Process & EnergyIs a business unit of