Propeller / Hull Status Report 2009
Propeller / Hull Status Report 2009
JUNE 2009
STORMFÅGELN AB (PUBL)
CONTENTS
Summary 3
Verification analyses that are
crucial for the Stormfågeln 5
Positive results from strength
and lifetime analyses 6
The “Stormfågeln Driving Unit
Transient Dynamic Analysis”
project 7
Competitive efficiency 8
The CFD-analysis of propulsive
efficiency 15
Further verifications planned
in the next stage 16
2
STATUS REPORT, JUNE 2009
Stormfågeln AB (publ)
SUMMARY
The Stormfågeln concept has several clear advantages over the main
technologies that are currently used for this type of marine traffic, such
as traditional propeller systems with straight shafts, water jet technol-
ogy, and traditional surface–piercing propellers. The advantages are
economic, environmental and performance-related. Work will now con-
tinue such that it will be possible during the autumn to confirm the ad-
vantages of the Stormfågeln over conventional systems. Potential OEM
partners will be courted in parallel with this, informing them of the new
and probably crucial facts that are presented in the interim reports.
CTD Marine has calculated that the efficiency of the Stormfågeln propeller is
62%, which agrees well with previous assumptions from field trials of the proto-
type Stormfågeln. The analyses suggest that there is a relatively large potential
for improvement, and CTD Marine believes that the efficiency of the propel-
ler can be increased to over 70% by optimising the blades. This figure is in line
with that achieved by other surface-piercing propellers. An efficiency of 70%
will mean that the Stormfågeln is in line with water-jet technology, the optimal
performance of which is calculated to be approximately 70% at its design speed.
It should be pointed out in this context that the optimised speed for water-jet
boats is normally set to lie between 30 and 40 knots. There are, furthermore, in-
dications that the efficiency of water-jet technology tends to decrease at speeds
above 40 knots.
3
The Stormfågeln concept has major advantages over both water-jet technology
and traditional surface-piercing propellers. The water-jet suffers from a low or
very low efficiency at all speeds apart from just the designed optimal speed, and
this means that the fuel costs are relatively high and thus also the impact on the
environment. Further, water-jet technology is sensitive to weight, and normally
needs extensive and expensive maintenance. The expense arises from, among
other factors, cavitation problems, which lead to damaging erosion when the
load deviates from what is suitable.
The pulsating forces that arise naturally when the propeller blades continuously
pass from air to water and from water to air are relatively low in the Stormfågeln
system, and thus the risks that the propeller blades are damaged or broken are
also low. This is otherwise a further weakness of the traditional surface-piercing
propeller technology.
4
VERIFICATION ANALYSES THAT ARE CRUCIAL FOR THE STORMFÅGELN
The measurements of fuel consumption that were carried out in October 2008
showed that the Stormfågeln concept is probably commercially interesting for
several segments within the marine industry. If a system, however, is to be used
for commercial marine transport, its strength, lifetime and maintenance require-
ments are critical. To put it another way: there are many good ideas that have the
potential to provide both environmental and economic advantages, but few of
them can prove that they are viable in the long run, and in daily commercial use.
The verification analyses that Stormfågeln started at the end of 2008, and which
were initiated by several potential OEM partners, are thus crucial for the future
of the Stormfågeln and the possibilities for the company to place its products on
the market. The analyses consist of five parts:
1. the propulsive efficiency of the Stormfågeln propeller
The performance of the 2. static calculations of strength and lifetime of the propeller blades and
Stormfågeln propulsor and its mechanism of the propulsor
propeller blades and mechanism 3. dynamic calculations of strength and lifetime of the propeller blades and
has been verified in a number mechanism of the propulsor
of analyses, presented on 4. optimisation analyses of propeller blades
26 May 2009. 5. comparative analyses of competing propulsions and hulls.
Of the five parts listed above, the efficiency has been determined and the static
analyses have been carried out. The results from these were presented as an in-
terim report on 26 May 2009 at IMES, the Institute of Mechanical Systems at
the Zürich University of Applied Sciences, which is responsible for the analyses
of strength and lifetime. The efficiency has been determined by CTD Marine,
Lennart Berghult Computational Turbomachinery Design, Switzerland.
The conclusions of the interim report allow us to conclude that the propulsion
of the Stormfågeln will satisfy the demands for lifetime required for commercial
marine transport. The Stormfågeln has thus passed a significant obstacle on the
pathway to commercialisation, and has been able to overcome an obstacle at
which many good ideas fall. Further, the efficiency that has been determined al-
lows us to see more clearly and to confirm the segments of the marine industry
in which the Stormfågeln will have the greatest competitivity.
5
POSITIVE RESULTS FROM STRENGTH AND LIFETIME ANALYSES
“We have carried out several analyses as a part of the project ‘Stormfågeln Driving Unit
Transient Dynamic Analysis’. Frequency and static stress analyses of the blades and mecha-
nism under dynamic load show that there are no critical weaknesses that cannot be solved
by minor design and/or material improvements. Based on the facts from these analyses and
a complementary fatigue analysis, our conclusion is that the Stormfågeln propulsion sys-
tem will meet the lifetime requirements. With the results from our next step – a dynamic
analysis – we will be able to determine the exact lifetime and make suggestions concerning
detailed design and material improvements.”
6
The loads have been applied as static loads in the computer model analy-
ses referred to by Professor Meier above. The next stage in the work is
constituted by dynamic analyses, in which the propulsor is rotated
while being subjected to varying loads. In simple terms, this means
that the frequency and static stress that arise when the parts are
in motion (which increases the tensions that affect the fittings)
are examined. The main aim of the dynamic analyses is to ob-
tain the background information required to optimise the de-
sign.
Lennart Berghult at CTD Marine has stated that it has been established that
the Stormfågeln possesses a robust system with respect to a long lifetime.
“The lifetime analyses carried out by the university are compatible with the standard
for lifetime calculations for commercial and military systems. The results are unambigu-
ous, and are of major significance in several respects. They indicate, for example, that the
maintenance cycles of the Stormfågeln are more advantageous than the cycles that can be
achieved by currently available water-jet applications. The Stormfågeln cycles are equiva-
lent to those used by robust conventional propeller systems used in vessels.”
Stormfågeln has developed contacts with several potential OEM partners. Dis-
cussions with these have come to something of a standstill while waiting for
the results of the strength and lifetime ana-
lyses. A positive result from these will prob-
ably determine the result of these discus-
sions. Stormfågeln has previously intended
to present the results once the study has
been completed. The conclusions reached by IMES
and CTD Marine, however, are so clear and unambiguous
that the company can proceed with the discussions now.
7
COMPETITIVE EFFICIENCY
The propulsive efficiency (the ratio between the power supplied and the power
delivered) of the Stormfågeln has been calculated, and used as a basis for the
analyses of strength and lifetime. The efficiency that the Stormfågeln currently
has and the potential optimisation of the blades have also given valuable infor-
mation about the performance of the Stormfågeln in comparison with compet-
ing systems, and thus also concerning the segments in which the concept of the
company will be most interesting.
This means that it is not possible to plot the graph of propulsive efficiency at
various speeds. CTD Marine, however, has drawn up a probable graph of the
propulsive efficiency of the Stormfågeln, based on the values that were measured
during the measurement of fuel consumption. An important fact on which this
graph is based is that the fuel consumption of the prototype is essentially con-
stant in the range of speed from 22 to 58 knots (where it is 4.1 litres per nautical
mile).
8
The CFD analysis shows that the propeller blades of the Stormfågeln have a
potential for improvement (see the box on Page 15 for details). It has been cal-
culated that it will be possible to improve the efficiency from its current 62% to
over 70%. The latter value corresponds to the efficiency of traditional surface-
piercing propellers. CTD Marine is of the opinion that it will be possible for the
Stormfågeln to reach this value, based on the optimisation potential revealed by
the CFD analysis, and based on the observation that the propeller blades of the
Stormfågeln are the result of “assumptions made during the design process and in the
absence of appropriate design tools”.
9
The Stormfågeln was run at tween the ideal values for the engine and the propeller in order to obtain optimal
58 knots during the electronic low fuel consumption.
measurements of fuel consump-
tion in October 2008, with short The Stormfågeln makes it possible to set this optimal compromise, and in this
spikes at 59 knots. way obtain the optimal low fuel consumption, independently of how the vessel
The consumption lay constant is loaded. Such an adjustment is not possible on installations that use water-jet
in the range of speeds 22-58 knots units or propellers with fixed blades (known as “fixed pitch” propellers). These
at approximately 4.1 litres per systems force the user to accept the parameters achieved at any one speed, and
nautical mile. the rate of revolution is determined by the current torque developed by the
propeller. This means, in turn, that it is only possible to optimise the propeller
for one speed. It is not possible to influence the fuel consumption at any other
speed.
10
A comparison of the Stormfågeln with conventional propellers:
COMMERCIALLY
Stormfågeln INTERESTING AT SPEEDS
vs Submerged ABOVE 30 KNOTS
Conventional Propeller
The diagram shows a compa- 0.80
The comparison shows that the Stormfågeln should be interesting for segments
that operate above 30 knots. This is the case for passenger ferries, for example,
and for military and paramilitary applications such as Coast Guard vessels. The
Stormfågeln may also be interesting for pure transport vessels such as supply
boats for merchant vessels and oilrigs. It may also be interesting for goods trans-
port with a high fuel efficiency that attempts to compete with road transport.
The efficiency in this comparison concerns also the propulsive force produced
by the propeller. Ocke Mannerfelt Design concluded in November 2008, based
on results from measurements of the fuel consumption of the prototype Storm-
fågeln, that the propulsion and hull of the Stormfågeln give an efficiency that
is 10% higher than the most modern drive technology in combination with a
well designed ventilated stepped hull, and 35% higher than conventional straight
drive shaft technology. The comparison shows that the Stormfågeln concept is
robust and lies in line with the latest technology. This comparison, however, is
rather like comparing apples and oranges. The most modern propulsion techno-
The Misago boat (where logy has not been designed for large vessels, while an installation with a straight
“Misago” is the Japanese drive shaft is not normally used for speeds above 30 knots.
word for “Stormfågeln”) is a
high-speed motor yacht that It is more interesting to compare the Stormfågeln concept with the systems that
IF Design has drawn, with are normally used for large vessels and for vessels that operate in the speed range
the propulsion and hull of the above 30 knots. Thus, the interest-
Stormfågeln. ing comparisons are those with other
surface-piercing propellers and with
water-jet technology.
11
Stormfågeln compared with a traditional surface-piercing propeller:
THE SAME Stormfågeln
OR BETTER EFFICIENCY – WITHOUT
vs Surface ANY Propeller
Piercing ACHILLES HEELS
Thus, the pitchable propeller blades are one of the strengths of the Stormfågeln
concept. They can be used:
• when reversing, with reverse thrust to achieve high manoeuvrability
• at the transition to the planing condition, by adjusting the ratio of the rate of
revolution of the engine to that of the propeller (the Stormfågeln requires
only a few boat lengths to achieve the planing condition), and
• when planing at different speeds, in order to adjust the ratio of the rate of
revolution of the engine to that of the propeller.
The CFD analyses also show that the pulsating forces on the propeller blades of
the Stormfågeln are relatively low. These forces, which arise when the propeller
blades continuously pass from air to water and from water to air, can cause the
propeller blades to become damaged or broken and are a further weakness of the
traditional surface-piercing propeller technology.
The ability of the Stormfågeln to reach the planing condition, to retain the plan-
A sequence from the CFD analysis ing condition at speeds that lie close to the threshold speed, the high manoeu-
of the propulsor of the Stormfågeln, vrability when reversing and the relatively low pulsating forces on the propeller
used to determine its propulsive blades all ensure that the Stormfågeln concept appears very advantageous when
coefficient. compared with the traditional surface-piercing propeller technology.
12
The Stormfågeln compared with water-jet technology:
SUPERIOR EFFICIENCY IN MOST SPEED RANGES
AND LOWER MAINTENANCE COSTSvs Waterjets
Stormfågeln
The diagram shows a compa- 0.80
It should be pointed out in this context that the optimised speed for water-jet
boats is normally set to lie between 30 and 40 knots. There are, furthermore, in-
dications that the efficiency of water-jet technology tends to decrease at speeds
above 40 knots. The curve presented by the Internal Towing Tank Conference
The original propeller blades presented above is based on theory, allowing a water-jet to be optimised for the
of the Stormfågeln have been top speed of the Stormfågeln, around 60 knots. This comparison between the
modified in several stages Stormfågeln concept and water-jet technology is based on this theoretical point.
according to a method based
on analyses of measured data, The Stormfågeln has considerable advantages over water-jet technology. The ef-
basic calculations, and trial ficiency of the Stormfågeln is higher in all speed segments, with the exception of
and error. The propeller blades the speed that is optimal for the water-jet.
have not yet reached their
optimal design, in their current A water-jet differs from traditional surface-piercing propellers and the concept
shape and size. CFD analyses of the Stormfågeln in that it has a high efficiency, and thus also a good fuel
have indicated that there economy, only at its optimal speed. Despite this, water-jet technology has today
remains potential for a strong position within the ferry segment and as an application for military and
improvement. paramilitary boats. The Achilles heels of the traditional surface-piercing propel-
ler technology (described on Page 12) are
a crucial factor in the general conclu-
sion that water-jet technology is a
better alternative.
13
Water-jet technology, however, also has weaknesses.
• The propulsor of the Stormfågeln is not sensitive to cavitation, but this can
constitute a major problem for water-jet technology, affecting its performance
and its potential need for maintenance.
• The design of a water-jet is adapted during its construction to the loads that
will influence the system at an optimal speed, and to the need to avoid cavita -
tion at this speed. Cavitation can have disastrous effects both on the efficie-
cy and lifetime of the system. The effect on lifetime arises since the cavitation
in a water-jet causes harmful erosion.
• To put it simply: this means that the maintenance requirements of water-jet
technology are normally sensitive to speeds and loads that do not correspond
to the optimal speed and calculated load. This may constitute, for example, an
A sequence from the CFD analysis
expensive limitation for shipping companies, since it means that they cannot
of the propulsor of the Stormfågeln,
optimise the load (made up of goods and/or passengers). The water-jet dis-
used to determine its propulsive
turbs stones and gravel from the water bottom, and this has a negative impact
coefficient.
not only on the environment but also on the costs of maintenance and of
inactive periods.
• Further, the hull of a water-jet vessel must be designed such that it avoids
mixing air into the water flowing around the water-jet unit. Thus, for exam-
ple, a modern high-efficiency hull with a ventilated stepped design is highly
unsuitable for use with water-jet technology. The propulsor of the Stormfågeln
does not suffer from these problems.
14
THE CFD ANALYSIS OF PROPULSIVE Efficiency
CTD Marine in Zürich has determined the propulsive efficiency during the development of the blade design, and this has been,
of the Stormfågeln based on values of speed, rate of revolution obviously, a limiting factor. This has led CTD Marine to the con-
of the propeller, and the shape and angle of the propeller blade. clusion that the propeller of the Stormfågeln can reach a propul-
The input values have been obtained from maximal load on the sive efficiency greater than 70%, given the correct optimisation.
propulsor with its propeller blades and mechanism. The speed in
this case was taken to be 58 knots. One indication of the potential for optimisation is the pressure
that the CFD analysis discovered on the suction side of the pro-
To put it simply: the propulsive efficiency is constituted by the peller blade, which gives a counteracting force. To put it simply:
power ratio between the power that is supplied to the propel- the boat is pressed backwards by this pressure and this reduces
ler (the torque multiplied by the rate of revolution) and the the propulsive efficiency. It is the opinion of CFD Marine that it
power that is delivered by the propeller (thrust multiplied by is possible to transfer this negative pressure to the forward pres-
speed). The CFD calculations have considered three media, and sure side of the blade by a redesign of the blade, and increase
this makes them very complex and advanced. Not only does the the efficiency in this way.
propulsor function in the interface between water and air layers,
cavitation also arises when the propeller blades move through There is probably further potential in an optimal adjustment
the water. This gives rise to a third medium, steam, which arises of the size of the blade. The surface area of the blade has been
when the pressure becomes so low that the water boils. gradually changed, and the blade profile was changed on one
occasion, using a trial and error method. It is impossible to
The propulsive efficiency of the Stormfågeln has been deter- determine whether the current size and shape are correct. What
mined to be 62% at a speed of 58 knots, which agrees well with we do know is that the current design is more efficient than pre-
the assumptions that were made in association with the tests vious versions. It will only be possible to determine whether the
of fuel consumption carried out in October 2008. CTD Marine efficiency can be increased by redesigning the form and profile
points out in its report that a number of probable optimisation of the blade in two ways: either by further CFD analyses or by
possibilities are available, which will increase the efficiency if casting a series of new blade sets. The CFD analyses are prefer-
carried out. A traditional surface-piercing propeller with well- able for several reasons – not least economic reasons. These
designed blades can achieve an efficiency above 70% at optimal analyses must also be carried out using trial and error, and they
speed. The propeller blades of the Stormfågeln are, as CTD have been included in the planned programme of verification
Marine expresses it, the result of “assumptions made during the for the Stormfågeln performance.
design process and in the absence of appropriate design tools”.
The Stormfågeln has had access to only a single set of blades
15
FURTHER VERIFICATIONS PLANNED IN THE NEXT STAGE
The evaluation presented in this status report shows that the Stormfågeln con-
cept is strong in those segments that operate in the speed range above 30 knots.
It shows also that the Stormfågeln has clear advantages over the systems that are
normally chosen for these segments.
16
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