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Specific fuel consumption graph for representative diesel generator versus engine speed and load left, examined SFOC curves of MAN 7S60MC — C8 engine (right). 

Specific fuel consumption graph for representative diesel generator versus engine speed and load left, examined SFOC curves of MAN 7S60MC — C8 engine (right). 

Contexts in source publication

Context 1
... combination with the rotational speed and the slip of the propeller, calculation of the actual rpm of the engine can be performed and the curve of engine-ship interaction can be plotted. Fig. 2 illustrates the effect that variations in engine loading have on specific fuel ...
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... of significant faults due to crew error. However, most differences can be explained due to sea and air inlet temperatures that affect the performance of the engine (MAN Diesel, 2007) and the actual operation in non- laboratory environment , which leads to an increase in the actual fuel consumption of up to 8% of the initial, as depicted in Fig. 2 ...
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... generators. This selection is made in order to have larger engines which consume less fuel and for which heat recovery is better. This enables the system to cover the working points as efficiently as possible. Any potential application of slow steaming is made more efficient, as the SFOC of all engines is at the minimum value as depicted in Fig. 2. Furthermore, there is the potential to overhaul the generators while the ship is in operation. Thus, using the already installed power and that this output has to be covered by the 85% output of the generators (optimum). Possible marine generator sets from two major manufactures are presented in Table 6. For shore applications, ...
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... P is the mean daily power and t 1 and t 2 are the time in days for the duration of the voyage. Thus, the energy requirements (integration results) are presented in Fig. 7 for three Post- Panamax ships used to illustrate the methodology. The hybrid system sizing utilises multiple diesel generator sets with different electrical output and energy storage devices such as batteries. The operational point of is taken as equivalent to the two-stroke conventional plant predicted by average loading in similar routes or by a smart controller. The latter will interpret data such as, state of charge of batteries, number of generators currently in operation, estimated time of arrival (ETA) at destination port and forecast of sea state. The decision constraints are the operation with the minimum number of generators and the likely demanded energy availability at the end or start of the voyage. The operation of the hybrid system is simplified as the engines operates in discrete stages of the previously installed power output (for the two-stroke engine), points that are highly optimised (minimum SFOC for stationary applications) by the engine manufacturers and produce constant amount of energy. These are referred as the ‘working points’ of the hybrid system. Table 5 represents the closest working point to the mean value of each voyage. Thus, the energy produced by the power output of the working point is considered to cover the average propulsion energy demand for the examined period. Importing the values from Table 5 and combined with the results of Figs. 7 and 8 is developed. This figure depicts the daily fluctuation of energy requirements for the vessel, if the hybrid propulsion system was in operation. The generators are set to produce the 80% of the conventional output. However, the requirements of propulsion vary with time. Consequently the energy storage medium, in order to keep the vessel speed constant, is required to supply energy for propulsion. In the ideal operation of the system, with no conversion losses and an immediate response of the controller, the green areas above and below each period of operation would be equal. This implies that after a voyage, the system will have run in optimum condition and the storage medium will be fully charged. As battery charge/ discharge conversion losses exist, these these areas have to be equal with respect to the conversion losses. This means that the charging area (above the operational point) is greater that the area below and this difference is equal to the loss of power times the hours of operation. Immediate conclusions for the energy storage installation and for the power output can be extracted. As can be observed from Fig. 8, the amount of energy that is available for storage, or is required to be supplied for the propulsion needs, is closely related to the working point of the engine as it was previously defined. The selection of this point can be further optimised and adjusted. Moreover, installation of a hybrid propulsion unit potentially allows the main engine to be smaller since in case of rough weather the extra amount of energy required for propulsion can be covered by the stored energy. The procedure to size the hybrid ship is separated into two major parts that are connected to each other. The first part is the selection and sizing of the diesel generator sets. The original ship design is assumed to remain constant so that the hull form and the propeller are unaltered. It is possible that further fuel savings may be made possible by subsequent modification to these areas (Molland et al., 2011). Hence, the overall system power delivered to the propeller remains the same. Potential reductions in the installed power will be as a result of optimised selection of both engines and storage medium. The installed engine onboard the examined Post-Panamax vessels is an MAN 7S50MC-C7 engine with Maximum continuous Rating (SMCR) of 11,060 kW at 127 rpm. The optimum point of operation is at 75% of the SMCR (MAN Diesel, 2007). A previous study (Dedes et al., 2010) showed that three preliminary scenarios of engine installation should be considered before simulating the overall system and running optimisation algorithms. This study is based on the scenario that the available power will be supplied by a total of six generator sets. With these six generators, 60% of the power will be supplied by two identical engines and the remaining 40% by four identical diesel generators. This selection is made in order to have larger engines which consume less fuel and for which heat recovery is better. This enables the system to cover the working points as efficiently as possible. Any potential application of slow steaming is made more efficient, as the SFOC of all engines is at the minimum value as depicted in Fig. 2. Furthermore, there is the potential to overhaul the generators while the ship is in operation. Thus, using the already installed power and that this output has to be covered by the 85% output of the generators (optimum). Possible marine generator sets from two major manufactures are presented in Table 6. For shore applications, optimisation at high single operational load is done, which results in further SFOC reduction and is applicable in hybrid propulsion system, as generator output is not altered. The loading difference, as it was previously explained, was multiplied by the MCR and the voyage time, in order to give the energy difference between production and requirement. These values are shown in Fig. 9, marked by the þ symbol. The diamond symbol represents every area above and below the constant energy production. In order to estimate the actual storage capacity of the system during voyages, a regression algorithm was created importing the statistic values of every vessel of a given type within the examined fleet. The first regression curve, depicted in Fig. 9, is based on the values denoted by the diamond symbol and the second is based on the daily energy difference. Additionally, the data presented with the diamond symbols relate to the ‘autonomy radius’ of the system and represent the ability of the system to cover the demand without alternating the production of energy by switching the generators on and off. In Fig. 9 the everyday energy report model is more accurate in the prediction of requirement than the total area energy model which overestimates the required energy due to the small sample inserted in the regression model calculation. With the aim of determining the required energy storage capacity, the propulsion designer has to define the vessel autonomy time. Autonomy time is set, to be the time (hours) before battery energy is depleted. In this work, a 200 h autonomy time of the system, is considered sufficient for bulk carrier applications. The results for ‘at sea operation’ for the rest of the fleet are summarised in Table 7. Although the energy storage requirements are summarised in Table 7, more aspects of energy availability have to be considered. It was previously mentioned that the batteries at the end of the voyage are fully charged. This requirement is justified by the existence of Emission Control Areas (ECAs). In these zones, an ‘emission free’ battery only operation is ideal. Thus, the energy storage system will supply sufficient energy to the vessel, either at normal voyage speed or at lower speed, until ship is berthed as well as to perform cargo handling. Moreover in certain sizing scenarios, sufficient stored energy has to available for departure without engine operation while the cargo handling had also been performed without ship engine operation. The latter potential is possible when harbours are equipped with ‘cold ironing’ facilities. Notwithstanding these variations in this study we concentrate on the voyage phase and assume that the battery system is fully charged at the beginning and end of each voyage. For the analysis of the performance of the hybrid propulsion system, a simplified model is used for the battery energy storage device. Although some aspects of performance will not be captured precisely, it should provide sufficient detail to size the system. It is assumed that the operation of an equivalent Diesel Electric system has the minimum SFOC of each vessel’s current propulsion engine. Although the engine shop test curve, shows that the SFOC curve is almost flat near the optimum area, the actual measured consumption differs significantly due to HFO operation and due to actual engine ship interaction. The sea and air temperature correction is assumed to make an insignificant contribution for the examined voyages. The overall battery performance cycle efficiency (charging–discharging) is considered constant for any discharge current and equal to 85% for redox flow batteries (Mohamed et al., 2009) and 92% for Sodium Nickel Chloride (Dustmann, 2004). These values for high instan- taneous discharge currents will drop but for over an overall cycle it should adequately represent the battery behaviour. The conversion losses from electrical to mechanical energy are typically 8–10%. These values depend on the individual electromechanical system. In this study, two scenarios were investigated as illustrated schematically in Fig. 10. The first scenario depicts an All Electric Ship (AES) vessel equipped with the four-stroke auxiliary generator engines of Table 6 and with motor/generator conversion losses equal to 8%. The second scenario can be identified as a theoretical two-stroke hybrid system with gearbox and electric motor similar to Power Take Off/In (PTO–PTI) systems that currently are under research and considered to offer gains in terms of safety and fuel consumption (Prousalidis et al., 2005). Battery efficiency issues have been accounted for in ...
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... ageing of the engines, poor maintenance and actual operation in non-ISO conditions result in a decrease of engine efficiency and increase of the SFOC. Consequently the ‘as measured’ fuel consumption will still imply a degree of uncertainty for the NO x emissions although the real engine would likely to emit more than that assumed in this study. This section presents the actual engine operation analysis applied to 31 separate voyages across five vessel types and for a variety of laden, and ballast conditions. Engine loading is calculated along with the actual energy requirements. Sizing of a replacement hybrid propulsion system is performed and energy consumption results for the total bulk carrier fleet are demonstrated. Daily ship performance data were collected from the technical department of a Greek Maritime Corporation. Each technical form includes the daily maintenance and monitoring logs together with operational orders for ship routing. These forms are commonly known as ‘noon reports’ and an example is shown in Table 4. The engine loading, as a percentage of the maximum continuous rating of the engine (MCR), was calculated by correlation of direct and indirect influence factors with the shop tests of the propulsion engine and the sea trials of the vessel. Direct influence parameters are the engine rpm, the Fuel Admission Lever, the Load Indicator and the rotational speed of the turbochargers. Secondary parameters are the slip of propeller, the ship’s speed, the wind direction and force, the sea condition, the current strength and direction. These parameters have an indirect influence in the correlation with the shop tests but are the main reasons why the engine loading varies. Direct influence factors are interpolated into the performance curves of the engine. The load indicator shows the desired engine loading, which shows the percentage of the MCR that the engine should be operating at. The fuel admission level shows the actual petroleum that is injected per cycle and hence the actual loading can be calculated. In practice, due to possible inaccuracies in the daily reports, this technique can introduce errors. The knowledge of the turbochar- ger rotational speed, which is unique to each engine load (except the loads requiring the use of the air blower), does allow a cross- check of the previously calculated value. In combination with the rotational speed and the slip of the propeller, calculation of the actual rpm of the engine can be performed and the curve of engine–ship interaction can be plotted. Fig. 2 illustrates the effect that variations in engine loading have on specific fuel consumption. These curves suggest that total emissions which are directly connected to the SFOC of the engine are dependent on the loading. Any transient operation away from the minimum, lead to increased SFOC, thus emissions in terms of g/kWh. Ship operation in calm sea has almost constant resistance for constant ship speed. When sea state is considered moderate or rough, added wave resistance is present. Hence thrust is increased, as the propeller is now not working at the design point, more fuel is injected into the engine to cover the torque and rpm demand. Sea motions affect this percentage of added resistance, while in extreme seas the propeller maybe partially outside the water. All this operation of the engine to cover the demand is considered transient, as the spectrum of waves is stochastic and irregular (Molland et al., 2011). Previous studies try to assume the engine loading and calculate indirectly the consumed fuel per voyage day by multiplying SFOC, engine loading factor, the kW of the engine’s MCR and the activity time (Corbett and Koehler, 2003) and (Endresen et al., 2003). This loading factor is found using (IMO, 2009) Actual speed Load Factor 1⁄4 ð 1 Þ Max : speed In this study the consumed fuel is reported and measured by the flow meters inside the engine rooms of each examined vessel. The knowledge of engine loading gives an initial approximation of the consumed fuel and allows the detection of significant faults due to crew error. However, most differences can be explained due to sea and air inlet temperatures that affect the performance of the engine (MAN Diesel, 2007) and the actual operation in non- laboratory environment , which leads to an increase in the actual fuel consumption of up to 8% of the initial, as depicted in Fig. 2 (right). The conventional diesel installation on-board bulk cargo vessels is a large two-stroke diesel engine (e.g. tankers, dry bulk ships), mostly without a generator attached to the main shaft, to cover the propulsion loads. The influence of weather on the performance of the vessel is important and previous work to estimate the magni- tude of these influences on vessel speed is summarised in Aertssen (1969). Fig. 3 illustrates the variance of engine loading from the optimum point and from each voyage mean loading (as found later in Fig. 6) of the examined Post-Panamax fleet. It can also be extracted from Fig. 4, there is a large range between the minimum and maximum reported values, while the difference from the maximum reported value to the MCR of the engine is also large. Typically, while sizing the propulsion unit, a margin is left so that the engine will operate at 85%, MCR in calm sea conditions at the service speed. The margin account up to 100% covers increased energy demands due to rough sea conditions and the progressive fouling of the ship hull (Molland et al., 2011). However, this point is not always the optimum point of operation of the engine, as may be found from the project guide of the installed two-stroke engine on the examined vessels (MAN Diesel, 2007), where the optimum loading is at 75% MCR. One other important aspect in the total power train is the loading of auxiliary engines. Fig. 5 demonstrates that auxiliary electrical demands do not regularly exceed 600 kW. Hence, every reported load above 600 kW will be considered as a ‘peak value’. Peak values are significant since at these times the output of a single generator is insufficient to cover the peak demands. Hence, coupling a second generator is required, causing the overall system to be partially loaded and at an inefficient operational point. This can significantly increase their specific fuel consumption, whilst the turbochargers of the engine will not be working near their surge line. The supply of air may be insufficient, further reducing the efficiency of combustion and smoke will be visible. Similar effects occur for the main engine operating at a reasonable distance away from its optimum. It is not possible to completely remove transient operation of the engines since when starting from cold conditions (idle and switched off) it takes time to increase the pressure and the temperature of the engine materials in stages so as to be ready to increase the load. A potential solution for transients during voyage could be the application of load levelling techniques using an appropriate storage medium (Hybrid System). Meanwhile the fully electrified vessel permits the uncoupling of loads and the engine and allows a more efficient handling of the complete power train. From Fig. 6 it can be observed that in every voyage of the Post- Panamax vessels within the fleet, the engine mean load varies from 70% to 80% of the MCR. Hence, the appropriate sizing of the main propulsion unit that could achieve a mean loading into that range, potentially the excess of produced energy in some cases can even that lack of required energy, achieving a NET energy demand equal to zero. Using the reported power requirements shown in Fig. 4, Eq. (2) is introduced, as from now; the hybrid system is examined from an energy ...
Context 6
... ageing of the engines, poor maintenance and actual operation in non-ISO conditions result in a decrease of engine efficiency and increase of the SFOC. Consequently the ‘as measured’ fuel consumption will still imply a degree of uncertainty for the NO x emissions although the real engine would likely to emit more than that assumed in this study. This section presents the actual engine operation analysis applied to 31 separate voyages across five vessel types and for a variety of laden, and ballast conditions. Engine loading is calculated along with the actual energy requirements. Sizing of a replacement hybrid propulsion system is performed and energy consumption results for the total bulk carrier fleet are demonstrated. Daily ship performance data were collected from the technical department of a Greek Maritime Corporation. Each technical form includes the daily maintenance and monitoring logs together with operational orders for ship routing. These forms are commonly known as ‘noon reports’ and an example is shown in Table 4. The engine loading, as a percentage of the maximum continuous rating of the engine (MCR), was calculated by correlation of direct and indirect influence factors with the shop tests of the propulsion engine and the sea trials of the vessel. Direct influence parameters are the engine rpm, the Fuel Admission Lever, the Load Indicator and the rotational speed of the turbochargers. Secondary parameters are the slip of propeller, the ship’s speed, the wind direction and force, the sea condition, the current strength and direction. These parameters have an indirect influence in the correlation with the shop tests but are the main reasons why the engine loading varies. Direct influence factors are interpolated into the performance curves of the engine. The load indicator shows the desired engine loading, which shows the percentage of the MCR that the engine should be operating at. The fuel admission level shows the actual petroleum that is injected per cycle and hence the actual loading can be calculated. In practice, due to possible inaccuracies in the daily reports, this technique can introduce errors. The knowledge of the turbochar- ger rotational speed, which is unique to each engine load (except the loads requiring the use of the air blower), does allow a cross- check of the previously calculated value. In combination with the rotational speed and the slip of the propeller, calculation of the actual rpm of the engine can be performed and the curve of engine–ship interaction can be plotted. Fig. 2 illustrates the effect that variations in engine loading have on specific fuel consumption. These curves suggest that total emissions which are directly connected to the SFOC of the engine are dependent on the loading. Any transient operation away from the minimum, lead to increased SFOC, thus emissions in terms of g/kWh. Ship operation in calm sea has almost constant resistance for constant ship speed. When sea state is considered moderate or rough, added wave resistance is present. Hence thrust is increased, as the propeller is now not working at the design point, more fuel is injected into the engine to cover the torque and rpm demand. Sea motions affect this percentage of added resistance, while in extreme seas the propeller maybe partially outside the water. All this operation of the engine to cover the demand is considered transient, as the spectrum of waves is stochastic and irregular (Molland et al., 2011). Previous studies try to assume the engine loading and calculate indirectly the consumed fuel per voyage day by multiplying SFOC, engine loading factor, the kW of the engine’s MCR and the activity time (Corbett and Koehler, 2003) and (Endresen et al., 2003). This loading factor is found using (IMO, 2009) Actual speed Load Factor 1⁄4 ð 1 Þ Max : speed In this study the consumed fuel is reported and measured by the flow meters inside the engine rooms of each examined vessel. The knowledge of engine loading gives an initial approximation of the consumed fuel and allows the detection of significant faults due to crew error. However, most differences can be explained due to sea and air inlet temperatures that affect the performance of the engine (MAN Diesel, 2007) and the actual operation in non- laboratory environment , which leads to an increase in the actual fuel consumption of up to 8% of the initial, as depicted in Fig. 2 (right). The conventional diesel installation on-board bulk cargo vessels is a large two-stroke diesel engine (e.g. tankers, dry bulk ships), mostly without a generator attached to the main shaft, to cover the propulsion loads. The influence of weather on the performance of the vessel is important and previous work to estimate the magni- tude of these influences on vessel speed is summarised in Aertssen (1969). Fig. 3 illustrates the variance of engine loading from the optimum point and from each voyage mean loading (as found later in Fig. 6) of the examined Post-Panamax fleet. It can also be extracted from Fig. 4, there is a large range between the minimum and maximum reported values, while the difference from the maximum reported value to the MCR of the engine is also large. Typically, while sizing the propulsion unit, a margin is left so that the engine will operate at 85%, MCR in calm sea conditions at the service speed. The margin account up to 100% covers increased energy demands due to rough sea conditions and the progressive fouling of the ship hull (Molland et al., 2011). However, this point is not always the optimum point of operation of the engine, as may be found from the project guide of the installed two-stroke engine on the examined vessels (MAN Diesel, 2007), where the optimum loading is at 75% MCR. One other important aspect in the total power train is the loading of auxiliary engines. Fig. 5 demonstrates that auxiliary electrical demands do not regularly exceed 600 kW. Hence, every reported load above 600 kW will be considered as a ‘peak value’. Peak values are significant since at these times the output of a single generator is insufficient to cover the peak demands. Hence, coupling a second generator is required, causing the overall system to be partially loaded and at an inefficient operational point. This can significantly increase their specific fuel consumption, whilst the turbochargers of the engine will not be working near their surge line. The supply of air may be insufficient, further reducing the efficiency of combustion and smoke will be visible. Similar effects occur for the main engine operating at a reasonable distance away from its optimum. It is not possible to completely remove transient operation of the engines since when starting from cold conditions (idle and switched off) it takes time to increase the pressure and the temperature of the engine materials in stages so as to be ready to increase the load. A potential solution for transients during voyage could be the application of load levelling techniques using an appropriate storage medium (Hybrid System). Meanwhile the fully electrified vessel permits the uncoupling of loads and the engine and allows a more efficient handling of the complete power train. From Fig. 6 it can be observed that in every voyage of the Post- Panamax vessels within the fleet, the engine mean load varies from 70% to 80% of the MCR. Hence, the appropriate sizing of the main propulsion unit that could achieve a mean loading into that range, potentially the excess of produced energy in some cases can even that lack of required energy, achieving a NET energy demand equal to zero. Using the reported power requirements shown in Fig. 4, Eq. (2) is introduced, as from now; the hybrid system is examined from an energy ...

Citations

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... From the figure it can be observed the very different trend of the BSFC contours and of the power limit curves that characterize the two engines versions (unfortunately similar data are not available for the GE12V228 engine). The BSFC contours of the 900 rpm Nmax engine (Fig. 2a) are characterized by a shape similar to that of most marine engines of the same category [5,6,10,11,12]. The BSFC contours of the 1000 rpm Nmax engine are instead characterized by a particular trend, that the authors have not found in any other similar engine with a single turbocharger. As shown in Fig. 2b, the BSFC contours characterized by a lower specific fuel consumption, have a tendency that brings them closer to each other near the power limit curve, when the engine speed decreases. ...
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In this study two four-stroke marine diesel engines, characterized by very similar nominal power and speed, but with very different trend of the power lint curve and specific fuel consumption contours in the engine load diagram, are compared by simulation, using each of them as an alternative to the other engine, for the motorization of a conventional (mechanical) propulsion plant for a small cruise ship. It is thus possible to determine and compare the efficiencies of the two engines and the vessel propulsion system overall performance for different ship speeds. The results of the comparisons are presented and discussed in the paper.
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