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Customer application 14 January 2021

Saving Fuel Made Easy

An important economic truth for slow-moving ships, like bulk carriers, is that small improvements to the hull can significantly decrease fuel consumption. A specialized monitoring system, designed by SkySails from Hamburg, has created the necessary informational foundation to implement this. It measures fuel consumption, then links this with all other factors that could be relevant for the most fuel-efficient ship operation.

Merely cleaning those ships that require it most would save a lot of fuel and money. But how can you tell which ships in the fleet are suffering from fouling, which often cannot be seen with the naked eye? “Fouling initially begins with a thin, bacterial film, which accumulates on the hull,” explains Falko Fritz, the manager for reporting at SkySails in Hamburg. The company made waves at the beginning of the 2000s with its towing kite for propulsion. The so-called Vessel Performance Manager (V-PER) is currently among the most successful products launched by the Hanseatic company. With its assistance, predictions can be made about when to send for the divers and their scrub brushes.

“Hull friction accounts for approximately 80% of drag in the case of slowly moving ships, like bulk freighters. Therefore, we can achieve large results through small improvements in the hull,” says Fritz. The flow measurement of the fuel forms the core of the V-PER monitoring system. SkySails then links this to all other factors that can influence fuel consumption.

Crews Can Learn From Each Other

It is a foundational concept that traveling slowly is the best way to save fuel. Everyone, who wants to analyze ship performance, has to bring fuel consumption into harmony with the prevailing hydrodynamics. This itself is formed from a mixture of many single factors which flow into the V-PER: speed, rudder angle, draught, the specifics of the routes and weather, and other influencing factors from ship operations. If the hydrodynamic relationships and the actual fuel consumption are available, SkySails can line up comparisons under normal conditions within a fleet and provide recommendations. Such comparisons are therefore always important, from the point of view of energy efficiency, so that crews can learn from each other. “There are shipping companies that have set up a positive competitions, along with corresponding training,” states Henning Kühl, manager for marketing and business development.

Performance monitoring systems, like V-PER from SkySails (brighter screen in the center of the picture) provide important information for operating ships more efficiently.

Gathering and Evaluating Data

The V-PER functions during operation on board with its own flow meter to measure fuel consumption. All of the data, which can contribute to a standardized evaluation of consumption, are either gathered on board by SkySails, or are provided to the company by the currently available systems. Draught, for example, can be derived from the loading computer; the ground speed and the speed through the water are available from the navigation systems. These are only two examples of functions that are incorporated into the performance monitoring system. To ensure availability of the data, SkySails uses the WAGO 750 I/O System as a central interface and gateway.

The greater the resistance posed by the ship’s hull, the higher the fuel consumption – big data provides the means for monitoring and optimization.

Flexible and Robust

The Hamburg company decided to use the WAGO system because it provides excellent flexibility and is incredibly robust. “I like to use the Universal Signal Conditioners with the 4-20 mA analog input. You can do a lot with that,” explains Mario Ladwig, manager for order development & services. If other signal types are needed, then SkySails simply uses the corresponding function cards from the WAGO I/O System. “This means that I can work very flexibly in the project; I can plan the control cabinet in advance and still be able to react at very late stages to requests from the ship owners. Adaptations can be easily integrated into the software.” For Steven Boneß, purchasing manager at SkySails, the reliability of the technology plays a major role when evaluating suppliers. “Any complaint on a sea-going vessel is extremely expensive. Therefore, everything has to function reliably, despite the salt in the air and the constant vibrations. WAGO components have done this for years, without any problems!”

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High Level of Operational Reliability on Board

The WAGO I/O System 750 is absolutely reliable, even during power outages. “These are not rare on board a ship, and occur whenever a generator supplying the on-board network fails due to an overload condition,” explains Fritz. After a network failure, which can last for up to a fifteen minutes, the SkySails systems has to correctly reboot all of the sensors, as well as their links to other systems, which can be quite challenging to implement. The WAGO I/O system is battery backed, in compliance with its classification, and thus rides out the interruptions until the on-board network is restabilized and available again – and the records from the point of breakdown are of special interest for subsequent analysis.

Economical and climate-friendly transportation remains an essential goal for ship owners.

Five Percent Less Consumption

Those who optimize their ships with V-PER quickly profit: According to SkySails, the system saves an average of five percent in fuel costs. Expressed in monetary terms: If a medium-sized container ship consumes 40 tons of fuel per day, and spends 250 days at sea, then this works out to 10,000 tons at 500 dollars per ton – thus around five million dollars annually. At a 5% reduction, that is, 250,000 dollars, the savings in one single year cover the investment costs for V-PER by a large margin, according to SkySails. And the company can prove these numbers through experience with more than 120 ships that are currently using the system.

The Benefits of V-PER in Overview:

  • Fast performance analysis

  • Simple fleet comparison

  • Flexible and robust hardware

Conclusion

The Hamburg company has created a solution with their performance monitoring system that provides valuable information based on comprehensive data. These can be applied immediately to adjust operations, and also for trend analysis and long-term improvements in efficiencies. It has been SkySail‘s experience that after installation of their solution, which is based on the WAGO 750 I/O System hardware platform, the ship’s owners are often surprised at how much information they previously lacked with regard to efficient ship operations, and how fast the savings accumulate. ’

Text: Steffen Friedrich, Global Key Account Manager Marine & Offshore at WAGO Kontakttechnik GmbH & Co. KG
Photos: SkySails

WAGO 750/753 I/O SYSTEM

Decentralized peripherals for every application: Boasting more than 500 I/O modules, programmable controllers and fieldbus couplers, WAGO’s remote I/O system offers all the functions required for your automation needs – and for every fieldbus.

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