A Framework for Energy Saving Device (ESD) Decision Making

Authors: J. H. de Jong, G.J.D. Zondervan

Presented by J.H. de Jong

Contents
1.
2. 3.

4.
5. 6.

Background Propulsion improvement Practical application of ESDs Approaches in retrofits and newbuildings Conclusions & future developments Discussion

Background

Fuel cost likely to increase further Emission regulations (EEDI) underway Operators challenged to improve ship propulsion Increasing concern also on underwater noise on marine life (!)

Background

Structural failure. [improved FEM] Lack of accuracy in full-scale measuring capability. [full scale monitoring] Lack of transparency of the savings in actual operational conditions. [new ops profile based approach] Limited insight into the detailed working principles of the devices and therefore a lack of ship-specific design capability. [CFD] Lack of ownership accountability. [EEDI]
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Approach
Below a typical approach is suggested for the selection and verification of ESD options: Select retrofit using data indicated by the owner/supplier; Optimize by applying CFD & check viability; the type and details of the hull form Model test to validate; Trial to confirm. the variations in draft/trim
the ship speed(s), the relevant operational circumstances
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Approach

Optimize by applying CFD & check viability; Model test to validate; Trial to confirm.
Getting confidence in the proposed ESD as a real energy saver.

Tuning the design of the ESD for the particular ship and its operation
Preparing for the interpretation of the efficiency gain predictions derived from model tests 6

Approach

Select retrofit using data indicated by the owner/supplier; Optimize by applying CFD & check viability; Model test to validate (incl. CFD); Trial to confirm.

Approach

Select retrofit using data indicated by the owner/supplier; Optimize by applying CFD & check viability; Model test to validate (incl. CFD); Trial to confirm.

MARIN has energy saving high on its agenda and currently runs a Joint Industry Projects (20 partners) called Refit2Save investigating: - Meewis duct - Rudder mounted post swirl stator - Ducted propeller - Hull vane

Majority of the ESDs improve the flow in front or behind the propulsor Energy saving and flow improvement (cavitation noise) Look at the overall efficiency
P E D P D
J K To 2 K Qo ( Po ) K Qo K T K Q K To ( R ) 1 t 1 w ( H )

(Hull resistance)

Propulsor-hull interaction

Majority of the ESDs improve the flow in front of behind the propulsor Energy saving vs. flow improvement (cavitation, noise) Look at the overall efficiency
P E D P D
J K To 2 K Qo ( Po ) K Qo K T K Q K To ( R ) 1 t 1 w ( H )
Non-uniformity (blades etc)

Axial losses

Rotation losses

Viscous losses (friction)

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Majority of the ESDs improve the flow in front of behind the propulsor Energy saving vs. flow improvement (cavitation, noise) Look at the overall efficiency
P E D P D
J K To 2 K Qo ( Po )
Wake adaptation

K Qo K T K Q K To ( R )

1 t 1 w ( H )

Hub shape

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Objective of ESD is to improve:

Propulsor efficiency or Propulsor hull interaction or both

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Propulsor efficiency

From basic axial actuator disc theory follows an ideal propulsor efficiency. Good propulsor designs are within a range of that ideal efficiency. Difference accounts various energy losses. Highest efficiency found for low thrust loading (CT = KT/J2)
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Propulsor efficiency

Swirl generating devices

Recover rotational energy losses by producing swirl velocity in opposite direction. Design result should be minimisation of rotational energy losses aft of the system. Rotational energy can be locked-up in the propulsion system.

Focus can be shifted in optimisation to minimisation of frictional energy losses. Optimum diameter decreases

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Propulsor efficiency

Rotational and viscous losses respectivey indicated by red and green arrows

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ESD examples

Swirl generating devices

Contra-rotating propeller Pre-swirl stators Post-swirl stators Grims vane wheel

Rudder bulbs Propeller boss cap fin (PBCF)

Propeller hub devices

Nozzles

Propeller nozzles Pre-nozzles (WEDs)

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ESD examples

Swirl generating devices

Contra-rotating propeller Pre-swirl stators Post-swirl stators Grims vane wheel

Rudder bulbs Propeller boss cap fin (PBCF)

Propeller hub devices

Nozzles

Propeller nozzles Pre-nozzles (WEDs)

DSME Pre-swirl stator

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ESD examples

Swirl generating devices

Contra-rotating propeller Pre-swirl stators Post-swirl stators Grims vane wheel

Rudder bulbs Propeller boss cap fin (PBCF)

Propeller hub devices

Nozzles

Propeller nozzles Pre-nozzles (WEDs)

Mitsubishi HI

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ESD examples

Swirl generating devices

Contra-rotating propeller Pre-swirl stators Post-swirl stators Grims vane wheel

Rudder bulbs Propeller boss cap fin (PBCF)

Propeller hub devices

Nozzles

Propeller nozzles Pre-nozzles (WEDs)

Nautican nozzle

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ESD examples

Swirl generating devices

Contra-rotating propeller Pre-swirl stators Post-swirl stators Grims vane wheel

Rudder bulbs Propeller boss cap fin (PBCF)

Propeller hub devices

Nozzles

Propeller nozzles Pre-nozzles (WEDs)

Mewis Duct

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Pre-swirl

Stator blades induce swirl velocity in front of propeller Pre-swirl flow is neutralized by the propeller Less kinetic energy remaining in rotating flow behind propeller Gains not only from recovery of rotation energy but also from reduced friction drag (smaller optimum propeller diameter) Gains reduced by reduced postswirl stator effect of the rudder
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Design procedure

Step #1 : Preliminary design using lifting-line model

Influence of many parameters to be explored Computationally inexpensive

Step #2 : Analysis and systematic variation using unsteady BEM Step #3 : Verification with viscous flow solver

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Design procedure

Step #1 : Preliminary design using lifting-line model Step #2 : Analysis and systematic variation using unsteady BEM

Propeller cavitation analysis Selection of final design variant

YX

Step #3 : Verification with viscous flow solver

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Design procedure

Step #1 : Preliminary design using lifting-line model Step #2 : Analysis and systematic variation using unsteady BEM Step #3 : Verification with viscous flow solver

Identification of flow problems Identification of scale effects in model experiments

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Design procedure

Step #1 : Preliminary design using lifting-line model Step #2 : Analysis and systematic variation using unsteady BEM Step #3 : Verification with viscous flow solver

Identification of flow problems Identification of scale effects in model experiments

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Design procedure

Step #1 : Preliminary design using lifting-line model Step #2 : Analysis and systematic variation using unsteady BEM Step #3 : Verification with viscous flow solver

Identification of flow problems Identification of scale effects in model experiments

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Model tests

Verification of design calculations

Model propulsion tests on vessel fitted with designed pre-swirl stator and 6 and 4 blade stock propeller 2.5 % power reduction gained for 6blade propeller (100.2 to 96 RPM) 5% power reduction for 4-blade propeller Efficiency gains and RPM drops indicate that design method is promising

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Some examples of stator integration

twin screw vessel with pre-swirl stator

Bulk carrier with a L-J Van Lammeren duct and pre-swirl stator
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ESD examples

Swirl generating devices

Contra-rotating propeller Pre-swirl stators Post-swirl stators Grims vane wheel

Rudder bulbs Propeller boss cap fin (PBCF)

Propeller hub devices

Nozzles

Propeller nozzles Pre-nozzles (WEDs)

Rudder stators & fins

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ESD examples

Swirl generating devices

Contra-rotating propeller Pre-swirl stators Post-swirl stators Grims vane wheel

Rudder bulbs Propeller boss cap fin (PBCF)

Propeller hub devices

Nozzles

Propeller nozzles Pre-nozzles (WEDs)

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ESD examples

Swirl generating devices

Contra-rotating propeller Pre-swirl stators Post-swirl stators Grims vane wheel

Rudder bulbs Propeller boss cap fin (PBCF)

Propeller hub devices

Nozzles

Propeller nozzles Pre-nozzles (WEDs)

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ESD examples

Swirl generating devices

Contra-rotating propeller Pre-swirl stators Post-swirl stators Grims vane wheel

Rudder bulbs Propeller boss cap fin (PBCF)

Propeller hub devices

Nozzles

Propeller nozzles Pre-nozzles (WEDs)

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Working mechanisms

Propulsion:

Torque reduction (Qf) Some thrust penalty (Tf) Reduction rotational loss (hub vortex)

Resistance:

Perhaps some reduced pressure drag of propeller hub due to removed hub vortex
Source:K. Ouchi et al. (Japan Society of Naval Architects and Ocean Engineers, 1992)

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PBCF seems cost effective and without risks. For the hydrodynamic mechanism to work:

Rotation losses of single propeller should be significant enough. Thus, the higher the loading at the inner radial profile sections the better. (not common feature for properly designed propellers) (maybe PBCF works best for dedicated propeller designs) Make the right comparisons! Large propeller hub diameter Notice that rudder is also recovering propeller rotational losses

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ESD examples

Swirl generating devices

Contra-rotating propeller Pre-swirl stators Post-swirl stators Grims vane wheel

Rudder bulbs Propeller boss cap fin (PBCF)

Propeller hub devices

Nozzles

Propeller nozzles Pre-nozzles (WEDs)

Nozzle on hopper dredger by IHC

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Propeller-nozzle combinations

Well-known Kort nozzle developed as early as the 1930s by Stipa and Kort. Nozzles begin generating sufficient amounts of thrust when the propeller suction is high enough. Can outperform open propellers when roughly the thrust loading CT > 1.5 - 2.5. However:

For structural reasons not accepted for large diameters. Nozzle supports can bring significant additional resistance. Key factor is proper integration of nozzle and ship hull ! (e.g. tunnels)

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ESD examples

Swirl generating devices

Contra-rotating propeller Pre-swirl stators Post-swirl stators Grims vane wheel

Rudder bulbs Propeller boss cap fin (PBCF)

Propeller hub devices

Nozzles

Propeller nozzles Pre-nozzles (WEDs)

Mewis duct

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ESD examples

Swirl generating devices

Contra-rotating propeller Pre-swirl stators Post-swirl stators Grims vane wheel

Rudder bulbs Propeller boss cap fin (PBCF)

Propeller hub devices

Nozzles

Propeller nozzles Pre-nozzles (WEDs)

Schneekluth duct
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ESD examples

Swirl generating devices

Contra-rotating propeller Pre-swirl stators Post-swirl stators Grims vane wheel

Rudder bulbs Propeller boss cap fin (PBCF)

Propeller hub devices

Nozzles

Propeller nozzles Pre-nozzles (WEDs)

Combined with fins

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Working mechanisms

Many possible working mechanisms:

Propulsion:

Wake concentrator:

D J KTo

K Qo KT K Q KTo

2 K Qo

1 t 1 w

Additional nozzle thrust due to foil lift. Possible contribution of pre-swirl in propeller plane

Hull resistance:

Flow alignment in axial direction (viscous and wave resistance) Possible prevention of flow separation (scale effects!)
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Model tests

Show distinct positive effect in order of 5% reduction of resistance (wake fraction). Influence on propeller performance. Scale effects are bound to exist.

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Numerical simulations

Given the many potential mechanism accurate simulation by CFD is demanding Nice pictures still requires verification and validation! Requirements:

Capturing of all relevant phenomena (vortices, separation, waves, flow interactions) Difficult due to unsteady parts
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Conclusions & future developments

Complexity of ESD design is shown. Numerical flow simulation brings a lot of new insight in flow mechanisms but capturing all relevant details is extremely challenging. Design & analysis procedures are being developed including quality standards in CFD. Fuel saving and reduction of underwater noise can go hand in hand using ESDs

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