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Customised Retrofit of Main Engine Control Systems for Passenger Vessel

Client

Blue Star Ferries / Attica Group

Location

Piraeus, Greece

Industry

Maritime

Asset Type

Propulsion Control System, Ro-Ro Passenger Vessel, Main Diesel Engines

Solution Category

Engine Control Systems, Main Engine Speed Control, Load Sharing Systems, Propulsion Control Retrofit, Woodward 2300E Upgrade

Customised Retrofit of Main Engine Control Systems for Passenger Vessel

Control system retrofit of the main engine speed control and load sharing system on Blue Star Mykonos, a Ro-Ro passenger vessel of the Blue Star Ferries fleet.

The project addressed the replacement of obsolete Woodward 721 control units, which were no longer supported by the manufacturer, creating long-term maintainability and lifecycle support risks.

The upgrade covered four Wärtsilä 12V38 diesel engines, with a total output of 31,680 kW, using custom-programmed Woodward 2300E control units.

MAS delivered a upgraded solution, designed to improve system reliability, responsiveness and long-term suppor, while maintaining compatibility with the vessel’s operational requirements.

The project included engineering, programming, installation, commissioning, dock and sea trials, and onboard crew training.

Key Outcomes

  • Replaced obsolete Woodward 721 controllers with modern Woodward 2300E control units
  • Modernised main engine speed control and load sharing for four Wärtsilä 12V38 diesel engines
  • Improved propulsion control reliability, system responsiveness and lifecycle supportability
  • Supported future scalability through integration with upgraded control cabinet infrastructure
  • Validated system performance through dock trials and sea trials
  • Strengthened onboard operational confidence through crew training and improved monitoring capability

Technical Capabilities Demonstrated

This project demonstrates MAS’ expertise in maritime propulsion control and main engine speed control retrofits and automation for vessels operating with obsolete legacy control systems. The Woodward 721 to Woodward 2300E retrofit combined load sharing systems, custom controller programming, PLC integration and engine control cabinet integration for Wärtsilä 12V38 diesel engine control in a demanding Ro-Ro passenger vessel propulsion control environment. MAS also delivered charge air pressure-based load sharing, governor and fuel rack compensation, CanBus communication, serial communication, Control Assistant monitoring, remote support capability, troubleshooting of vessel system interfaces, dock trials, sea trials, commissioning and onboard crew training.

Customised Retrofit of Main Engine Control Systems for Passenger Vessel

Customised Retrofit of Main Engine Control Systems for Passenger Vessel Download the Full Case Study for deeper technical details, system architecture and project outcomes




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