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SUPPORTING THE ENERGY EFFICIENT SHIP DESIGN PROCESS WITH ENERGY FLOW
SIMULATIONS: CASE EFFICIENT COOLING WATER SYSTEM
M Elg,Deltamarin Ltd. and VTT Ltd., Finland
M Kuosa, K Tammi, Aalto University, Finland
P Mkipeska,Deltamarin Ltd., Finland
A Kinnunen and P Rahkola, VTT Ltd., Finland
SUMMARY
The ship energy flow simulator, developed originally by Deltamarin, ABB and VTT, was utilized for evaluating the
potential in the cargo ship fresh cooling water system, considering the individual requirements from the various components
in the cooling system. With the tool, the main topology for an efficient cooling water system could be demonstrated. The
system consists of a balanced ring network with an optimal set-up of pumps and heat exchangers that were dimensioned for
both minimizing the building cost and performing best at the average operation conditions, instead of the extreme design
conditions. The cooling system is controlled by varying both flow rate to components and return temperature to the central
cooler according to the operation profile. This new design method can efficiently support the ship design work already at the
crucial concept development phase, where the main decisions regarding ship energy efficiency are made.
This document is formatted in the convention required for all conference papers
central cooler heat exchanger and the sea water cooling 2.1 INPUT DATA
pumps. Sea water cools down the LT-water that is
circulated through various heat exchangers in the ship A bulk carrier vessel, B.Delta 37 was used as a case shipin
machinery and other systems. In the current systems there this study. The machinery of the case ship consists of one
is a temperature-controlled by-pass line on the LT-side so slow speed diesel main engine, sized 6050kW, for
that a part of the water can be circulated past the central producing the necessary propulsion power for the ship with
cooler. The LT-water is also utilized for cooling down the directly coupled fixed speed propeller. The electricity for
high temperature (HT) water in the main engine. Figure 1 the ship auxiliaries and other processes is produced by
below illustrates the main components in a cargo ship three medium speed diesel auxiliary generator engines,
cooling water circuit. 740kW each.
The energy balance calculation for the case ship [6] was
utilized for the study as initial data. This data consists of
the average estimated operational profile of this ship type,
the propulsion power requirements for the various load
conditions, as well as the average electricity and heat
requirements for the ship processes and the ship machinery
parameters. Furthermore, this data together with the engine
operational data from the engine manufacturer [8,9] was
used as an input to the calculation in the ship energy flow
simulation environment.
For simplicity, the calculations and the case study were
made in ISO ambient reference operational conditions
[10]. In practice this was considered for the engine
Figure 1: The main components in a cargo ship cooling parameters, such as the charge air coolant temperature and
water system. turbocharger air intake temperature of 25C.Table 1
presents the main operational values used in the study for
The energy saving possibilities in this system emerge from the ship cooling water system, where each row describes
the possibility to control the flow with variable-speed an operational situation or dimensioning conditions. The
pumps in both LT- and sea watercircuits for minimizing the first column shows the operation hours at the various
flow through the central cooler by-pass line and for operational modes, and the following columns include the
maximizing the fluid temperature differences over the average heat power from each main component in the
central cooler.This general saving potential can be cooling system that is studied. The last column summarizes
demonstrated with simple energy balance calculations. the total amount of heat from the cooling system that is
Assuming that the temperature differences over the central cooled by sea water at the central cooler. The first row
cooler on both sides can be increased, the preliminary describes the dimensioning, thus, tropical conditions that
estimations for the theoretical saving potential resulted in are the basis for dimensioning the equipment in the cooling
over 4% yearly fuel saving in ISO conditions on an circuit and the second row shows, for reference, the
average route [6]. Practically, however, evaluating the true cooling system values for full load on main engine. The
energy saving potential in this system is difficult, as the main engine load has, thus, a large impact to the entire
LT-water cooling system affects strongly in many of the cooling system.
key components in the ship machinery. According to the operational profile, the main engine load
This topic was studied briefly by Elg et al. with a ship varies between 40% and 75% at sea. In port, only the
energy flow simulation tool [7]. One of the interesting auxiliary engines are utilized.
findings was that once the main engine efficiency was The sea water and LT-water pump capacities were based on
enhanced by lowering the temperature of the LT-water, the reference design values of the case ship, and the
possibilities for lowering the speed of the sea water (SW) dimensioning is based on the design conditions with
cooling pump are restricted. This phenomenon is, almost 100% load on all equipment, adding still some
therefore, important to be included in the models for fouling margin on top of this.
studying the improvement potential in the ship cooling
water systems.
The purpose of this study was to create a simplified model
containing the main characteristics of the cooling water
system, for presenting solutions that improve the ship
energy efficiency. Therefore, the ship energy flow
simulation platform that was earlier created for
B.Deltabulk carrier vessel [7] was extended further for the
purpose.
2. CASE DESCRIPTION
F
igure 2: The principal topology of the low temperature
cooling water system
m
p
P= (1)
where is the density of the fluid and 0 < < 1 denotes
the efficiency of the pump. In this study, a constant value
of 0.6 was assumed for both LT-water and sea water
cooling pumps for describing the total efficiency of the Table 3 shows that in the current modelthe cooling water
pump, including motor losses. p is the pressure difference system pipes and thethrottling valves create often the
required for the pump, and this value depends on the total largest pressure differences.
system design. For the preliminary calculations in the
study, the reference values from the case vessel design 2.3 SAVING CASE
material were used to describe the pressure loss in the LT-
water and sea water pumps. The design pressure loss for 2.3 (a) Pump control principles and possible piping
the LT-water pump was 3bar and for the sea water pump configurations
2,5bar, and they are mainly based on the requirements for
the main engine. Energy saving possibilities in the ship cooling water
Further limitations for the parameters in the model were a system, after considering the global effects of LT-water
maximum temperature of46C for the sea water after settings, are related to minimizing the pump electricity
central cooler. Following this limit, the maximum consumption. This can be affected by aiming for a
temperature of the LT-water was set to 50C. These balanced piping solution that includes minimal pressure
limitations are based on recommendations from heat losses in the system and lowering the cooling pump speed
exchanger manufacturer regarding the sea water and where possible with frequency converters. On the sea
reference design data for the processes. water side, aiming for maximizing the temperature
difference of the sea water over the central cooler results to
2.2 (c) Initial results and findings lowered speed of the pumps. In the traditional cooling
system designs, the temperature of the LT-water is kept
The pressure in the LT-water system was set to 4bar and constant at all operational conditions, and this set up
the pressure lift of the LT-pump varied mostly between allows altering the sea water pump speed quite freely
2,2-3 bar, as a function of the utilization of the central outside the dimensioning, namely tropical conditions, and
cooler by-pass line. Figure 3 presents the pressure of the the savings are considerable in cooler operational
LT-water both at the inlet and outlet of the LT-pump.Table conditions, since there is always a relatively large
3 presents the average drop in pressure over the cooling temperature difference between sea water and LT-water.
system heat exchangers. However, if the temperature difference between sea water
and LT-water is very small constantly for maximizing
engine performance, as described in section 2.1 Input data,
the possibilities for lowering sea water pump rpm are
restricted. In this case,and with full speed of the pump on
the LT-water side, the possibilities to lower rpm on the sea
water pump are mainly related to minimizing the flow
through LT-water by-pass line over the central cooler.
require from the actual system set consumption this would be over 200t/a, if producing the
upthree pumps that could each be ship electricity with auxiliary engines.
dimensioned according to 50% of the
total flow required in the partial LT- Table 4: Results of simulation. The description min. flow
cooling system. For the sea water pump a referes to the lowest limit where the flow can be reduced in
calculational minimum flow of 10% was the pump in question. The results are presented as energy
assumed, for exploring the possibilities consumption for the individual pumps, in kWh and the fuel
to reduce flow in the case study consumption due to the pumping is evaluated in the last
conditions. Also this would require column, in t/a.
several pump units in the actual
instalment. Regarding the LT-pump that
was named as constant speed pump in
Figure 5, also this pump set up was
assumed to be realized as a configuration
that could actually consist of two larger
pumps for operation at sea and one
harbour pump. This enables smaller flow
in the system when main engine is not
operated.
o 3.b: This case was otherwise similar to
3.a, but the minimum flow limit for the
speed controlled LT-water and SW-
pumps were, respectively, 50% for the
LT-pump and 25% for the SW-pump.
This set up would enable lower number
of installed pumps.
at detail level for being able to evaluate the full potential of 11. MAN DIESEL & TURBO, Service Letter
the system. SL2014-589/MTS, (2014)
2. HATAMI, M., GANJI, D., GORJI-BANDPY, M., Mia Elg holds the current position of Development
A review of different heat exchangers for Manager, regarding energy and environmental efficiency at
increasing the diesel exhaust waste heat recovery, Deltamarin. She is also a part-time research scientist at
Renewable and Sustainable Energy Reviews,2014. VTT and commits her PhD-studies at the Aalto University.
During the past years, her main tasks at Deltamarin have
3. BALDI, F., GABRIELII, C. A feasibility analysis included, for instance, various energy balance analysis,
of waste heat recovery systems for marine feasibility and R&D studies for adapting new energy
applications, Energy, 2015 saving or emission reduction technologies in ships and
offshore vessels. She has also conducted audits and
4. KAKALIS, N., DIMOPOULOS, G., -trainings, related to fuel saving, energy efficiency or ship
STEFANATOS, I., A Novel Framework for process optimization for different ship owners. Mia's
Dynamic Modelling of integrated Machinery current work both at Deltamarin and VTT is mainly related
Systems, COMPIT 2014 conferenceproductions to a joint development project together with other
companies and research institutes for improving ship
5. ZOU, G., KINNUNEN, A., TERVO, K., energy efficiency, for example with simulation assisted
ORIVUORI, J., VNSK, K., TAMMI, K., ship design.
Evaluate Ship Energy Saving Scenarios Using
Multi-Domain Energy Flow Simulation, COMPIT Maunu Kuosaholds the current position of project
2014 conferenceproductions researcher at Aalto University. He is responsible for
research projects and teaching. His previous experience
6. ELG, M., KUOSA, M., LAMPINEN, M., includes, for example,heat transfer and district heating.
LAHDELMA, R., MKIPESKA, P., RAITA, J.,
ZOU, G., TAMMI, K., Advanced auxiliary Kari Tammiworks as an Assoc. Prof. in design of
cooling system for energy efficient ships, mechatronic machines at the Aalto University, Finland. His
EEMODS 2015 conferenceproductions research interests include powertrain, power transmission,
and energy efficiency research. The applications vary from
7. ELG, M., QUACH, S.,ZOU, G., KINNUNEN, A., electrical motor, electrical vehicles to ship power systems.
TAMMI, K., Improvements in Machinery Design He has earlier worked for VTT Technical Research
of a Bulk Carrier by utilizing Multi-Domain Centre of Finland, North Carolina State University, USA,
Energy Flow Simulation, COMPIT 2014 and CERN European Laboratory for Particle Physics,
conferenceproductions Switzerland.
8. MAN DIESEL & TURBO, Main Engine Room Panu Mkipeskahas the current position of Senior
Data calculations for 5S50ME-B9.3-TII, (2014) Machinery Engineer at Deltamarin Concept Department,
responsible for ship concepts machinery specifications and
9. MAN DIESEL & TURBO, L23/30H Project development in machinery sector. His major previous
Guide Marine Four-stroke GenSet compliant experience is from different positions at Finnish shipyards
with IMO Tier II, (2014) during 23 years + 9 years at Deltamarin Concept
Department.
10. MAN DIESEL & TURBO, Influence of Ambient
Temperature Conditions, Main engine operation Aki Kinnunenworks as a Senior Scientist at VTT
of MAN B&W two-stroke engines, (2014) Technical Research Centre of Finland Ltd.He is
responsible for full scale measurements, system simulation
and marine propulsion ice load simulation at VTT. His
previous experience includes working in shipyard and in responsible for modelling and simulation of dynamic
pulp&paper industry. machine systems. His previous experience includes
dynamic energy system simulations of ships and vehicles.
Pekka Rahkolaworks as a Senior Scientist at VTT
Technical Research Centre of Finland Ltd.He is