ΕΛΙΝΤ 2016 Pariotis Et Al Presentation

22 - 23 November 2016, Eugenides Foundation, Athens, Greece
A Simple Methodology for the Evaluation of Installing

Variable Speed Drive Pumps on the Central Cooling
System of Existing Ships
Efthimios G. Pariotis
email: pariotis@snd.edu.gr
T.C. Zannis, J.S. Katsanis and E.A. Yfantis

Section of Naval Architecture & Marine Engineering
Hellenic Naval Academy
Outline/Agenda
Why focus on Energy Savings in Ships ?
Scope of the Study
Description of a Central SW/FW Cooling System
Why Use Variable Speed (VSD) SW Pump ?
Evaluation of VSD Pump Technology
Results and Discussion
Conclusions
Indicative Examples of Real World VSD Applications

Outline/Agenda
Scope of the Study
Conclusions

Energy Saving in Ships
The strict environmental regulation established worldwide and the recent economic crisis
motivated the shipping industry for implementing operational and technical measures
towards the reduction of the total ships energy demand and fuel consumption
Until recently, the majority of the proposed techniques were restricted on:
the ship hull / propeller hydrodynamic optimization and
on the improvement of the main and auxiliary diesel engines efficiency,
since the potential cost savings in these areas are significant.

Current trend
Nowadays, partly owing to the advances in the control technology, there is an increasing
interest on optimizing the operation of less power demanding components installed on a
ship which have a relatively high contribution on the total ships energy consumption due to
their lengthy operational period.
Such a component is the central cooling seawater pump, which in general is considered to
operate at:
constant speed ,
on a permanent basis.
Outline/Agenda
Scope of the Study
Conclusions

Scope of the Study
Present a simple methodology adequate to be implemented on existing vessels, to

estimate the potential improvement on the electric energy consumption that is expected
by installing a variable speed drive motor on the central cooler seawater pump.
Doing this, it becomes feasible to adjust the pump speed and the seawater volume flow
rate, according to:
the actual temperature of the seawater (heat receiver), as well as
the instantaneous total heat load and minimize the SW pump power consumption.
Outline/Agenda
Scope of the Study
Conclusions

Typical seawater (SW) central cooling system

Typical seawater (SW) central cooling system

Typical Variation of Sea Water Temp. / HX Cooling Load

Outline/Agenda
Scope of the Study
Conclusions

Why Using Variable Speed Drive (VSD) SW Pump ?
Affinity Laws for Pumps

Example: A 30% reduction of Mass flow rate corresponds to 66% reduction of Pump Power
Required

Affinity Laws for Pumps


For systems where friction loss predominates, reducing pump speed moves the intersection
point on the system curve along a line of constant efficiency.
The operating point of the pump, relative to its best efficiency point, remains constant and
the pump continues to operate in its ideal region.

For systems where friction loss predominates, reducing pump speed moves the intersection
point on the system curve along a line of constant efficiency.
The operating point of the pump, relative to its best efficiency point, remains constant and
the pump continues to operate in its ideal region.
Outline/Agenda
Scope of the Study
Conclusions

Evaluation of VSD Pump technology Typical Approaches
In general there are two approaches followed by the engineers to evaluate the
effectiveness of incorporating the VSD technology for the control of cooling systems in
marine applications.
Model-based approach Data-driven models
Modeling the cooling system based on Using data (measurements) provided
first principles physical models by properly installed temperature and
pressure sensors
Conventional Model Based Approach
In most model-based studies published, the performance of heat exchangers is not

directly determined according to their technical specifications and the temperatures /
flow rates of the fluid streams involved, but it is pre-determined.
The required SW mass flow rate at part HX cooling load is calculated based on the energy
conservation equation.
Energy Conservation Equation
! " =>
! "
Result:
The role of heat-exchanger is over-simplified without
being able to calculate the actual effect of changing the
mass flow rates (FW/SW) and the inlet temperatures on #
the heat exchanger effectiveness and performance.

Proposed Evaluation Method
In the present study, a model-based approach is demonstrated, while the performance of

the SW/FW cooler is analytically determined under variable inlet fluid streams
conditions, i.e.:
SW and FW Temperatures (In/Out)
SW and FW mass flow rates

-"
1 1
$ $ ) ) +,
&'( &*
U 0 , , # , # ,
Fluid Properties)
SW circuit Conventional Case Constant Speed Pump
The SW pump operates at constant speed SW mass ow rate ( ) is constant and the
temperature of the seawater exiting the central cooler varies with:
the cooler heat load and
SW inlet temperature
345 6*785 4 .
SW circuit Variable Speed Drive Pump
The pump speed is adjusted, SW mass ow matches the actual central cooler heat
Load, taking into account the SW inlet temperature and keeping the SW exiting
temperature as close as possible to the set-point required by the engine manufacturer (in
the present study : ; <= ?@ oC).
345 6*785 4 . 50 oC)

LT FW circuit
FW temp. is controlled by a three-way valve. In general there are two options:

The 3-way valve is continuously adjusted to
maintain the temperature level at 36 oC, or
The 3-way valve keeps the heat exchanger

by-pass line always closed, except only when
the SW temp.< 6 oC to ensure that the FW
temp. at the heat exchanger outlet is > 10 oC
(set-point)
50 oC
C 36 oC.
Heat Exchanger Modeling
The overall heat transfer coefficient U is calculated using:
-"
1 1 H
$ ) ) +,
&'( &* I
SW side FW side
The fouling resistance +, 0.000176 [K*m2/W] according

to (TEMA, 1999)
Convection heat transfer coefficient for the tube-side (SW) fluid flow ]^
Gnielinskis correlation approximates 90% of the published results with 20% accuracy:
0Q +4 ! 1000 6S
OP "
N 2
If Re M 1 10 0Q
1 ) 12.7 6S T ! 1
2
If Re U 1 10 N OP 0.023 +4 V.W 6S V.W
where XY Z
6S
[
The heat transfer coefficient for the SW-side fluid flow &' is calculated by:
&' \'
OP
[
Heat Exchanger Modeling Fluid Properties
All fluid properties, i.e. thermal heat capacity ` , viscocity a and conductivity b, are
calculated at the mean SW temperature :
")
_ 2
All the fluid properties (seawater or fresh water) are calculated using the expressions
proposed by (Kishor G. Nayar et.al 2016, M.H. Sharqawy et.al, 2010 and IAPWS 2008),
taking into account the fluid temperature, pressure and salinity (in case of seawater)
Convection heat transfer coefficient at the shell-side (FW) fluid flow ]
A simple expression proposed by (Kern D. 1954) for a shell with 25 % cut segmental baffles,
is used:
V."N
&( \c V.dd V.TT
Z
0.36 +4C 6S
[ Ze
Heat Exchanger Modeling Effectiveness n
The effectiveness (n) of the central cooler is a function of:
op
the number of transfer units O $ _qY rst
_qY rst
the heat capacity ratio +f
_qY ruv
1 ! hi + f j ! 1 ! hi j
for + f g 1 h
1 ! hi + f j ! + f 1 ! hi j
8 hi
for + f
1 h
1 ) 8 ! 1 hi
2
hi
1 ) exp !O $/8 + f ) 1
1) +f ) +f )1
1 ! exp !O $/8 + f ) 1
Heat Exchanger Modeling Effectiveness n Effectiveness of the Heat Exchanger
The effectiveness (n) of the central cooler is a The effectiveness of the central
function of: cooler is related to the heat load :
op
the number of transfer units O $ h
_qY rst _'j C" ! "
_qY rst
the heat capacity ratio +f 0 h, , , # ,
_qY ruv
Fluid Prop.)
n=0 O $, +
+ 0 , , # , # )
O $ 0 $, min , # # )
-"
1 1
$ ) ) +,
&'( &*
$ 0 , , # , # ,Fluid Properties)
Solution Procedure
Steps Initial Values (Independent Variables): _|}p~ , " , C" , #
1. Guess Values for C ,
2. 0 ", , # 0 C" , C
3. _|}p~ Ce ! " => =..
4. -"
1 1
$ $ ) ) +, C"
&'( &*
U 0 , , # , # ,Fluid Properties)
5. h=0 O $, + 0 , , , , Fluid Properties) C
# #
6.
h _|}p~
_'j C" ! " "
7. Ce ! "
8. # # # C" ! C C
Check Converge ?
_|}p~
Check Check if uv
, C # uv
(if not, change )
Check Check if _|}p~ (if not, change )
Solution Procedure
Independent Variables Symbol
SW Inlet Temperature "
FW Inlet Temperature C"
Mass flow rate of FW #
HX Heat Load _|}p~
Calculated Variables Symbol

SW Outlet Temperature
FW Outlet Temperature C
Mass flow rate of SW C"
Checking Parameter Criteria Accomplished C

SW Outlet Temperature |'_' c
50 oC _|}p~
|'_' c "
FW Outlet Temperature 36 oC
Outline/Agenda
Scope of the Study
Conclusions

SW circuit Heat Exchanger Specifications
Design Conditions of the Central Cooler

Heat Exchanger
: Heat exchanger Cooling capacity 4251 kW
Tube Side Fluid Seawater
Shell Side Fluid Fresh water
U: Overall Heat Transfer Coefficient 2354 W/m2K
Heat Transfer Exchange Area 376.83 m2
: SW mass flow rate 56.48 kg/s
# : FW mass flow rate 47.07 kg/s
" : SW Inlet Temperature 32.0 oC

: SW Outlet Temperature 50.0 oC
C" : FW Inlet Temperature 57.6 oC
C : FW Outlet Temperature 36.0 oC

Logarithmic Mean Temperature Difference 5.60 oC
(LMTD)
LMTD Correction Factor F 0.8541
Shell cut segmental baffles 25%
Estimation of the required SW mass flow rate

1. Operation of HX at Full Heat Load
A. Typical Constant Speed SW Pump
B. VSD Pump. Conventional method to

determine ; (Energy Balance Equation)
C
B _ ~_c_
! "
C. VSD Pump. Proposed method (Iterative

procedure taking into account the HX
variation of effectiveness as a function of
changing conditions): _ ~

1. Operation of HX at Full Heat Load
A Conclusions
The calculated SW mass flow rate when
VSD pump using the Conventional and
the Proposed method are almost
identical
C
B
The required SW Mass Flow Rate reduces
approx. 51% at ,'j 13 oC compared
to the one at ,'j 32oC.
Almost 88% reduction of the Pump

power (based on the affinity law, without
taking into account the reduction of the
efficiency due to the VSD drive motor)

2. Operation of HX at Part Heat Load
A. Typical Constant Speed SW Pump
B. VSD Pump. Conventional method to

determine ; (Energy Balance Equation)
C
_ ~_c_
! "
B C. VSD Pump. Proposed method (Iterative

procedure taking into account the HX
variation of effectiveness as a function of
changing conditions): _ ~

A Conclusions
There is a higher potential for further
reduction of SW mass flow rate compared
to the full load case (approx. 70%
reduction of the SW mass flow rate)
C
The using the proposed method (C)
is higher than the one obtained using the
conventional one (B), with the difference
B being higher at high SW temperatures.
This difference is mainly due to the effect

of SW flow rate on the HX overall heat
transfer coefficient.

44 kg/s
; %
C
@%
33 kg/s
17 kg/s
; ?%
16 kg/s
%
Estimation of LT FW stream Temperatures

3. Estimation of the FW Temperatures (Full HX Load)
FW Inlet Temp
A
FW Outlet Temp
A

3. Estimation of the FW Temperatures (Full HX Load)
C Conclusions
The Set Point Temperature Criterion is
FW Inlet Temp accomlished: C 36 oC
A
36 oC
C The FW outlet temperature is higher in
case of using the VSD motor compared
30 oC
FW Outlet Temp with the ones corresponding to the
A constant pump speed.
17 oC

3. Estimation of the FW Temperatures (HX Part Load)
C FW Inlet Temp
C FW Outlet Temp
A

3. Estimation of the FW Temperatures (HX Part Load)
Conclusions
C FW Inlet Temp
FW inlet and outlet temperatures when
the VSD motor is used are almost
A constant at all SW inlet temperatures
(with the proper adjustment of the SW
mass flow rate), satisfying the set-point
temperature restriction that have been
C set i.e. C 36 oC and 50 oC
FW Outlet Temp
A
Estimation of SW stream Temperatures

4. Estimation of the SW temperatures (Full HX Load)
SW Outlet Temp
A
SW Inlet Temp
A C

4. Estimation of the SW temperatures (Full HX Load)
Conclusions
C
SW outlet temperature is close to the
max. allowed ( 50 oC) for all the SW
inlet temperatures examined => Explains
SW Outlet Temp
A the almost identical estimated
between the Conventional (B) and the
Proposed method (C).
SW Inlet Temp
A C

4. Estimation of the SW temperatures (HX Part Load)
Conclusions
C 45 oC
SW outlet temperature is a little bit lower
than the max. allowed Set Point
48 oC
SW Outlet Temp ( 50 oC). Varies between 45,4 oC and
48,12 oC. => This explains the deviations
observed with the between the
A Conventional and the Proposed method.
SW Inlet Temp
A C

4. Estimation of the SW temperatures (HX Part Load)
Conclusions
C 45 oC
SW outlet temperature is a little bit lower
than the max. allowed Set Point
48 oC
SW Outlet Temp ( 50 oC). Varies between 45,4 oC and
48,12 oC. => This explains the deviations
observed with the between the
A Conventional and the Proposed method.
SW Inlet Temp
A C
Outline/Agenda
Scope of the Study
Conclusions

Conclusions
A model-based approach is demonstrated for the evaluation of the prospected techno-
economic benefit of using a VSD motor for the SW pump of a central cooling system
installed on a vessel
It has been demonstrated that significant techno-economic benefits (approx. 60%-80%) can
be expected using a VSD SW pump.
The advantageous feature of the proposed method, is that the energy balance equations are
dynamically linked with the actual heat exchanger performance (depending on the
boundary conditions, i.e. mass flow rates and temperatures) leading to a more precise
estimation of the required SW mass flow rate as a function of the SW inlet temperature,
taking into account all the restrictions of the problem (set-point temperatures for SW and
FW outlet temperature )
Using a VSD motor for SW pump speed control, leads to higher LT FW temperatures, which
may affect negatively the bsfc of the main engines of a vessel in case the cooling systems
have been designed to take benefit of as low as possible cooling temperature for the charge
air cooler.
Outline/Agenda
Scope of the Study
Conclusions

Examples of Current Commercial Applications (1/2)

Examples of Current Commercial Applications (2/2)

A Simple Methodology for the Evaluation of Installing

Variable Speed Drive Pumps on the Central Cooling
System of Existing Ships
Efthimios G. Pariotis
email: pariotis@snd.edu.gr
T.C. Zannis, J.S. Katsanis and E.A. Yfantis

Section of Naval Architecture & Marine Engineering
Hellenic Naval Academy

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22 - 23 November 2016, Eugenides Foundation, Athens, Greece

A Simple Methodology for the Evaluation of Installing

T.C. Zannis, J.S. Katsanis and E.A. Yfantis

Scope of the Study

Description of a Central SW/FW Cooling System

Why Use Variable Speed (VSD) SW Pump ?

Evaluation of VSD Pump Technology

Results and Discussion

Indicative Examples of Real World VSD Applications

Scope of the Study

Description of a Central SW/FW Cooling System

Why Use Variable Speed (VSD) SW Pump ?

Evaluation of VSD Pump Technology

Results and Discussion

Indicative Examples of Real World VSD Applications

Energy Saving in Ships

since the potential cost savings in these areas are significant.

Scope of the Study

Description of a Central SW/FW Cooling System

Why Use Variable Speed (VSD) SW Pump ?

Evaluation of VSD Pump Technology

Results and Discussion

Indicative Examples of Real World VSD Applications

Scope of the Study

Present a simple methodology adequate to be implemented on existing vessels, to

Scope of the Study

Description of a Central SW/FW Cooling System

Why Use Variable Speed (VSD) SW Pump ?

Evaluation of VSD Pump Technology

Results and Discussion

Indicative Examples of Real World VSD Applications

Typical seawater (SW) central cooling system

Typical seawater (SW) central cooling system

Typical Variation of Sea Water Temp. / HX Cooling Load

Scope of the Study

Description of a Central SW/FW Cooling System

Why Use Variable Speed (VSD) SW Pump ?

Evaluation of VSD Pump Technology

Results and Discussion

Indicative Examples of Real World VSD Applications

Why Using Variable Speed Drive (VSD) SW Pump ?

Affinity Laws for Pumps

Why Using Variable Speed Drive (VSD) SW Pump ?

Affinity Laws for Pumps

Why Using Variable Speed Drive (VSD) SW Pump ?

Why Using Variable Speed Drive (VSD) SW Pump ?

Scope of the Study

Description of a Central SW/FW Cooling System

Why Use Variable Speed (VSD) SW Pump ?

Evaluation of VSD Pump Technology

Results and Discussion

Indicative Examples of Real World VSD Applications

Evaluation of VSD Pump technology Typical Approaches

Conventional Model Based Approach

In most model-based studies published, the performance of heat exchangers is not

the heat exchanger effectiveness and performance.

Proposed Evaluation Method

In the present study, a model-based approach is demonstrated, while the performance of

SW and FW Temperatures (In/Out)

SW and FW mass flow rates

SW circuit Conventional Case Constant Speed Pump

the cooler heat load and

SW circuit Variable Speed Drive Pump

345 6*785 4 . 50 oC)