Case Study. On-board Engine Tuning Using NO x. & CO 2 Monitoring To Reduce Fuel Consumption. MV Copiapo Evolution EMS Fuel Savings Trial Report SO X

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1 Case Study On-board Engine Tuning Using NO x & CO 2 Monitoring To Reduce Fuel Consumption MV Copiapo Evolution EMS Fuel Savings Trial Report On-board NO x CO 2 SO X Emissions Monitoring

2 Contents 1.0 Introduction Purpose of the Trial Subject Vessel & Monitoring System Method Initial NOx Technical Code Compliance Verification Initial Fuel Consumption Measurement Engine Optimisation Procedure Post-Optimisation Fuel Consumption Measurement Results Analysis of Results Reduced Fuel Consumption Reduced CO 2 Emissions Compliance with NO x Emissions Limits Combustion Quality System Rental Testimonial Contact Us... 12

3 1.0 Introduction Evolution EMS is a NO x / CO 2 emissions monitoring and engine optimisation system designed for vessels to comply with MARPOL Annex V1 Regulation 13, The NO x Technical Code and MEPC. 103(49). Four years of product development were followed by extensive testing both on-board vessels and on engine test beds, to prove its suitability for the hostile marine environment. The system is the first of its kind in the world to be Type Approved in fulfilling this complex legislation. 2.0 Purpose of the Trial Evolution EMS system enables operators to optimise engine performance on-board by monitoring NO x & CO 2 emissions to deliver major fuel savings. Historically engines were always supplied tuned to operate with the lowest fuel consumption in what is known as economy mode, with no restrictions on NO x control regulations from the IMO, engines were required to be de-tuned to what is known as low NO x mode to reduce their emissions. Unfortunately as fuel combustion is less efficient in low NO x mode, these engines now use more fuel - typically 4 to 5% more fuel as supported by the engine manufacturer s own data. By using Evolution EMS on-board, operators are free to retune their engine back towards its economy mode whilst still remaining within the allowable emissions limits and so achieving major fuel savings. 3

4 Case Study The purpose of the trial was to prove the fuel saving capability of on-board engine optimisation using Evolution EMS NO x / CO 2 monitoring system to deliver an independently audited set of results showing the fuel saving achieved. 4

5 3.0 Subject Vessel & Monitoring System MV Copiapo is a 5,500 TEU container ship, owned by CSAV of Chile and managed by Peter Dohle Schiffarts KG of Germany. Built by China Shipbuilding Corporation in Taiwan, MV Capiapo was delivered to its owners in Evolution EMS NO x / CO 2 emissions monitoring system was installed to optimise the performance of the Sulzer 10RTA96-C main engine and comprised of the following components: Heated sample probe (in exhaust duct penetration); Heated sample line (clipped to tray work); Evolution EMS central control cabinet (engine control room) incorporating; - NO x & CO 2 analysers - Gas conditioning system - Bespoke Type Approved software - Touch screen user interface Engine condition sensors* Ambient condition sensors* Fuel flow transmitters* *All these items are mandatory system components in accordance with MARPOL Annex VI Regulation 13, The NO x Technical Code and MEPC.103(49) 4.0 Method 4.1 Initial NOx Technical Code Compliance Verification On commissioning of the Evolution EMS system to the satisfaction of the Chief Engineer, the specific NO x output (gkwh) of the main engine was measured in accordance with the procedures defined in MEPC.103(49) - Guidelines for Using Direct Measurement & Monitoring. Additional checks were carried out on the engine to verify that all operating parameters were adjusted in accordance with allowable values for NO x compliance in accordance with the engine technical file. 5

6 4.2 Initial Fuel Consumption Measurement Whilst the vessel was on a long transit (12 hours or more at 100% NCR) the fuel consumption measurement and engine optimisation were started. Independent fuel measurement systems were used as dual verification of fuel consumption to ensure accurate audited results. With the engine and vessel operating at steady state conditions, the fuel consumption was accurately measured over a 4 hour period. The Chief Engineer independently confirmed the accuracy and repeatability of both independent fuel measurement systems for absolute verification. 4.3 Engine Optimisation Procedure With reference to the original engine settings, checks and discussions with the engine manufacturer, the range of permissible engine adjustments was determined and agreed. These engine adjustments addressed both mechanical and electronic setting adjustments. The Martek project engineer together with the vessel s Chief Engineer then proceeded to make the agreed adjustments to restore the operating efficiency of the main engine to the maximum permissible, with reference to the measured NO x and CO 2 levels on the Evolution EMS system. The adjustments were performed in small steps to ensure that under no circumstances were any of the physical limit conditions of the engine approached. The complete engine optimisation procedure was completed within a period of 2 hours. 4.4 Post-Optimisation Fuel Consumption Measurement The fuel consumption of the engine after optimisation was measured in the same way as described in section 4.2. The specific NO x output (g/kwh) of the main engine was measured in accordance with the procedures defined in MEPC.103(49) - Guidelines for Using Direct Measurement & Monitoring. 6

7 5.0 Results The average fuel saving achieved across the four trials was 1.72% 7

8 6.0 Analysis of Results 6.1 Reduced Fuel Consumption The specific fuel oil consumption of the engine was reduced by an average of litres per hour during the trials, representing a 1.72% saving. Expressed in financial terms for the subject vessel, this would represent monthly and annual savings of: Monthly saving on fuel US$ 26,961* Annual saving on fuel US$ 323,532* *Based on 300 days operation with average bunker cost of US$330 / tonne 6.2 Reduced CO 2 Emissions As CO 2 emissions are directly proportional to specific fuel oil consumption, it follows that the CO 2 emissions of the engine were reduced by 1.72%. This equated to reduced CO 2 emissions of ~13 tonnes per day reducing annual emissions by ~4000 tonnes. 6.3 Compliance with NO x Emissions Limits The specific NO x emissions of the engine remained in compliance with the prescribed limits after the engine was optimised. 6.4 Combustion Quality With reference to the Evolution EMS trial results, it can be seen that the quality of the combustion was significantly improved. The blue line represents the pressure in one of the cylinders before optimisation plotted against crank angle, whereas the red line represents pressure in the same cylinder post-optimisation. It can clearly be seen that post-optimisation, the maximum achieved pressure in the cylinder was higher at a given load, which gives a clear indication of better combustion and therefore improved efficiency. In the optimised state it can also be seen that the rate of increase of pressure was steeper, again indicating improved combustion. The Evolution EMS trial results also shows that pre-optimisation (blue line), the cylinder pressure actually falls due to a delay between fuel injection, representing inefficient combustion. The post-optimisation (red line) shows no such delay after optimisation has been achieved demonstrating improved efficiency of combustion, and therefore reduced fuel consumption. 8

9 The trial successfully proved the theory of on-board engine optimisation to deliver major fuel savings using NO x / CO 2 monitoring system. Installation of Evolution EMS system was carried out without disruption to the vessel s operating schedule. Similarly, the engine optimisation procedure was undertaken without disruption to the vessel s operating schedule. The fitting of the Evolution EMS system and the optimisation of the engine was carried out with the approval of the engine manufacturer and did not in any way compromise the engine manufacturer and did not in any way compromise the engine warranty. All other engine settings and operational parameters remained within normal operating ranges after the optimisation procedure and it was generally observed that the engine was operating better. All engine optimisation adjustments were made well within the safe operating limits of the engine. Indeed it is recognised that on the subject vessel there is significant scope for further optimisation of the engine, with greater adjustments to approach the safe operating limits. The results proved that the operator would recover their investment on Evolution EMS within six months and deployment of the system would save potentially US$ millions in the lifetime of the vessel. By using Evolution EMS the vessel is freed from the onerous, disruptive and potentially risky parameter check compliance method and is free to source spare parts in the open market from sources other than the original engine manufacturer. 7.0 System Rental Evolution EMS system is avaliable on a rental option, which overcomes the purchase coming out of your capital budget. Typical monthly lease costs are a fraction of what you will save on fuel by fitting Evolution EMS. The immediate net contribution to the profitability of your vessel is extremly significant by deploying Evolution EMS. Taking into consideration the net technical, commercial, logistical and environmental benefits... Can you afford NOT to fit Evolution EMS? 9

10 8.0 Testimonial Peter Dohle Schiffahrts Fleet Manager Mr. Kurt Brieger commented on the trials: Peter Dohle Schiffahrts and Martek Marine undertook a detailed programme of trials to establish the scope of fuel savings achievable on-board MV Copiapo through engine optimisation using Evolution EMS Engine Emission Monitor. The equipment was installed, in-passage by the Martek Marine service team with assistance of the ship s engineers. The installation did not affect the vessel s operation. Various trials were carried out on the main engine (Wartsila 10RTA96-C) to measure NO x / CO 2 and F.O consumption. The trials concluded that fuel savings in the range 0.6% % were delivered. The main engine was monitored for specific NO x emissions throughout the trials and was proven to be in compliance with the limits in the NO x Technical Code both before and after each trial. 10

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