Fishing Vessel Energy Audit Project

Transcription

1 Fishing Vessel Energy Audit Project Mike Gaffney, C.E.M., C.E.A., C.P.Q. USCGLicensed Chief Engineer, Unlimited HP Exec VP Engineering, Alaris Companies November 20, 2014 Seattle, WA

2 Outline Energy Efficiency: The Big Picture Baseline: Why Do We Need One? Hull Power and Engine Efficiency A/C Power D/C Power Refrigeration System Hydraulic y System Goal: Reduce Cost

3 Ship Energy Efficiency: The Big Picture & losses and waste (next page)

4 Baseline Reference point in which analysis is done Better baselines provide better information for informed decisions Purpose of doing energy survey Energy Analysis Tool (E.A.T.): Helps fisherman develop their baseline of energy cost Fuel Use by Operating Mode Fuel Use by Load Type Transit Propulsion Longline Freeze Troll Ice Troll Misc Fishing propulsion DC Load AC Load Hydraulic Load Rfi Refrigeration i F/V Example, E.A.T. Summary

5 Baseline: Energy Audit Measurements Energy Audit Measurement Accuracy Relative Accuracy Absolute Accuracy Measurement instruments Torque Meter Power Quality Meters Amp Meter Voltage Meters Infrared Camera

6 Torque Meter Measuring Engine Shaft Horse Power Propeller Shaft Power Measurements: 8 Fishing Vessels Strain Gauge installed on Shaft Intern Jacob Installing Strain Gauges on F/V Salty

7 Engine Fuel Efficiency Brake Specific Fuel Consumption (BSFC) Engine Efficiency: i Conversion of energy in fuel into useful work Lb of Fuel / HP hr produced Kg of Fuel/ kwh produced Factors Effecting BSFC Load on Engine Air Temperature Condition of Engine

8 Engine and Vessel Performance Curves

9 Woodstock 220hp 4 Cycle Cummins NH220 BS SFC (g/kwh h) Shaft Power (HP) Cents/kWh

10 140 Woodstock 39 Power vs. Speed (HP) aft Power Sh Speed (kts)

11 2,500 Woodstock Fuel Cost/1,000 miles 2,250 2,000 1,750 uel Cost ($ $) F 1,500 1,250 1, Speed (kts)

12 ) Fuel Co onsumption n (Gal/NM Woodstock, Stabilizer and Fuel Penalty Fuel Cost: 1,000 6kts With: $1,600 Without: $1,000 Difference:$ Speed (kts) Woodstock no stabilizers With Stabilizer

13 F/V Myriad Speed Efficiency vs. Engine Efficiency Sha aft Power (HP) BS SFC (g/kwh h) Shaft HP BSFC Speed (kts) 200 Engine Not Optimized for Normal Operating Speed

14 F/V Myriad : Most Economical Speed Main Engine Fuel Cost vs. Total Cost $7.00 $6.00 Cost ($/N NM) $5.00 $4.00 $3.00 $2.00 $ Speed (kts) Total (Maint & Fuel) /NM Main Engine fuel $/NM Energy Analysis Tool Includes User Defined Maintenance cost

15 Energy Analysis Tool F/V Myriad Main Engine Maintenance Input Page #1 Main Engine Maintenance Interval (hrs.) Cost ($) Hourly Cost $/hr. Oil Change 300 $ $0.67 Minor Overhaul 5,000 $1, $0.30 Major Overhaul 30,000 $25, $0.83 Annual Misc. Repair 1,200 $ $0.42 Other 0 $0 #DIV/0! Other 0 $0 #DIV/0! Total $2.22

16 1000 F/V Topaz (78, 1,000 HP): Shaft HP vs. Speed Shaft Power (H HP) Speed (kts)

17 Diesel Generators Inverters Loads: Motors Lights Heaters A/C System: Generation and Load

18 Electrical Equipment Efficiency Torque Energy from Engine Heat Losses Transmission 2 to 30% Heat Losses 1-2% Generator Electrical Energy when converted from one form to another by electrical equipment has an associated efficiency (waste energy). Transformer Heat Loss 2-30% Heat Losses: Up to 98% Light ballast and bulb Heat Loss: 2-40% Electricity Transformer Useful work, Motor Light Heat Heat Loss: Loss 5-20% Pump Fan 5-20% Fluid Movement Air Movement

19 F/V Savage Aux Power: 105 kw and 55 kw Gensets Ene ergy Cost ($/kwh) Generator Load (kw)

20 Meas sured Load (kw) 5545 kw kw kW F/V Savage Aux Load 2 day Trip 55 KW Cat Genset Vessel Load $0.28/kWh $0.32/kWh $0.41/kWh $0.66/ kwh

21 10545 kw Savage: Aux Load 2 Day Trip 105 kw Cat Genset Vessel Load Meas sured Load (kw) kw kW $0.29 kwh $0.34/kWh $0.46/kWh

22 Engine Efficiency and Costs Cost with Cost with Cost with Load Annual 105 kw 55 kw 55 kw and (kw) hours Engine Engine 10 kw Engines $3,780 $3,690 $2, $5,460 $4,900 $3, $850 $750 $ $1, $1,050 $1,050 Total $11,253 $10,390 $8,370 Savings $2,883

23 A/C Power from Inverters Square Wave Issues with sensitive gear Increases c energy e consumption o Lowest Cost Modified Wave Less equipment sensitive Better efficiency Modest cost True Sine Wave No issues with sensitive gear Same or better than shore power Best efficiency for gear Highest g Cost Efficiency and impact on cost example to follow in next section Square Wave Inverter Shore Power

24 Motor Efficiency

25 Motor Efficiency and Savings 88% Standard Efficient Motor - 15 HP Circulating Pump Input Power: HP Cost for 2000 hrs/yr (23%) operation: $8, % Premium Efficient Motor - 15 HP Circulating Pump Input Power: HP Cost for 2000 hrs/yr (23%) operation: $8,475 Annual Savings: $423/yr Initial Cost: $1,600 Motor Life: 10 yrs Annual ROI: 16.4% Payback: 3.78 yrs 10 Year Motor Life Cycle cost Energy Purchase Install

26 Motor Efficiency and Savings 68% Standard Efficient Motor - 1 HP Circulating Pump Input Power: 1.47 HP Cost for 2000 hrs/yr (23%) operation: $768 Purchase Price: $ % Premium Efficient Motor - 1 HP Circulating Pump Input Power: 1.21 HP Cost for 2000 hrs/yr (23%) operation: $626 Purchase Price: $446 Annual Savings: $141/yr Cost Difference: $125 Motor Life: 10 yrs Annual ROI: 102.7% Payback:.89 yrs

27 VFD for S.W. Cooling Pump Reduce Centrifugal Pump Speed by ½ = Power and Fuel Consumption reduced to 1/8 MOTORS CONTROL Motor Variable Frequency Drives (VFD) Steering Gear, Fans, Pumps, Winches

28 1 F/V Topaz Steering Gear Po ower (kw) :24 14:52 15:21 15:50 16:19 16:48 17:16

29 F/V Savage Steering Gear #1 and # (kw) Powe Date and Time

30 VFD on Hydraulic Steering 70% Reduction in Energy Usage ER (KW) POWE TRADITIONAL HYDRAULIC STEERING $4,500 in Fuel / 5,000 hrs VFD CONTROLLED STEERING GEAR 1.0 W) POWER (KW $1,125 in Fuel / 5,000 hrs

31 Alternator and Drive Belt Efficiency DC Power Generation

32 DC Power Generation Belt Losses: Engine to Alternatort 93% 95% Efficiency Varies by: Belt Type Tension Pulley Size 98% Slippage decrease efficiency ~5% Energy Loss and Efficiency of Power Transmission Belts, Third World Energy Engineering Congress, The Association of Energy Engineers

33 Alternator Efficiency: Load and Speed Properly Size Alternator White Paper: Improving Alternator Efficiency Measurably Reduces Fuel Cost: Mike Bradfield, MSME, Remy Inc

34 DC System Alternator t Efficiency: i 45% to 85% DC Load: Ave. 800 Watts Hours Fishing and Transit = 1,549 hrs Engine BSFC 228 g/kwh = $0.29/kWh Fuel Cost before Alternator Losses: $360 Alternator input power for 800 Watt: 45% Efficient: 1,778 Watts 85% Efficient: 941 Watts Baseline From McCrea Energy Analysis Tool

35 DC Generation Efficiency Comparison McCrea DC Load from Energy Analysis Tool: Ave 800W Hours Fishing and Transit = 1,549 Energy Cost: Engine BSFC 228 g/kwh = $0.29/kWh Fuel Cost before without Losses: $360 Engine Power to Belt Drive 45% Efficient Alternator (1,775 W) V Belt 90% Efficiency: 1,976 W Fuel Cost: $857 Energy Cost: $0.69/kWh Engine Power to Belt Drive 85% Efficient Alternator (941 W) Synchronous Belt 98% Efficiency: 960 W Fuel Cost: $408 Energy Cost: $0.32/kWh Savings with Efficient Equipment: $449/year

36 Inverter Efficiency Comparison: : Fuel cost for 1,000 Watt (1 kw) load for 1,000 hrs being charged by alternator on engine Older 80% efficient Inverter DC Input Power : 1,250 Watts Engine Power (Alternator Efficiency 50%): 2,500 Watts Total Efficiency: 40% $/kwh fuel cost with engine at $0.40kWh = $1.00 kwh Total Fuel Cost: $1,000 New 95% efficient inverter: DC Input Power: 1,052Watts Engine Power (Alternator Efficiency 70%): 1,502 Watts Total Efficiency: 66% $/kwh cost with engine at $0.40kWh = $0.60 kwh Total Fuel Cost: $600 Low Loaded diesel Genset: $.90/kWh and Up plus Maintenance ($1.50/hr to $2.25/hr): $2.40.kWh Total Fuel and Maintenance = $2,400 to $3,150

37 Refrigeration System Compressor Efficiency Maintenance Operating Pressure F/V Born Again

38 Maintenance vs. Technology Compressor Power on Reefer Containers Cumulative Energy 24 Hours Faulty Door Seal E N E R G Y ~ 10 years technological l improvement

39 35 F/V Topaz RSW Compressor: Power and Compressor Discharge Pressure PSI: $18,000 Fuel /2,000 hrs of operation Pow wer (kw) PSI 140 PSI: $13,800 Fuel/2,000 hrs of operation 15 10:22 10:24 10:27 10:30 10:33 10:36 10:39 10:42 10:45

40 Efficiency Viscosity Cleanliness Hydraulic Systems El Rio: Belt Driven Engine Mounted Hydraulic Pump

41 Hydraulic Systems F/V McCrea Propeller Shaft Powe er (HP) Hyd Engaged Hyd Washdown Pump on Pump off Hyd Disengaged Hyd Engaged Engaged Hydraulic System Losses Engaged Hydraulic System Losses Produces 2.24 kw of Waste Heat

42 Hydraulic Systems: F/V Myriad Measured Activity Fuel (GPH) Change (GPH) Trolling with hydraulics OFF 1.47 Trolling with hydraulics ON Trolling while Running Gear w Hydraulics Name (eg. Ice troll, gillnet, Propulsion Engine #1 Operating Mode family outing) Hrs Transit Hrs Fishing 1 Longline Ice troll Freeze troll family Total Energy Analysis Tool Vessel Profile Page Ave Hourly Hydraulic Loss Cost: $1/hr No Load Hydraulic Fuel Cost on All the Time (1,205 hrs): = $1,205 Only Engage Hydraulics When Needed for Useful Work

43 Thank You!

44 Back Up Slides

45 Radio: HP vs. Speed Sh haft Power (HP) Speed (kts)

46 F/V Radio Speed Efficiency vs. Engine Efficiency M Gallons/N BSFC (g/kw Wh) Speed (kts) Gal/NM BSFC g/kwh Gal/NM BSFC (g/kwh) 200

47 (HP) Total Sh haft Power F/V Savage: Shaft HP vs. Speed Speed (kts)

48 F/V Savage Ship Efficiency vs. Engine Efficiency Main Engin ne Fuel ($/N NM) $9.00 $8.00 $7.00 $6.00 $5.00 $4.00 $3.00 $2.00 $ BSFC (g/kwh) $ Speed (kts) 200

49 F/V Salty (42ft. Gillnetter): Shaft HP vs. Speed Shaft Power (HP P) Speed (kts)

50 140 F/V El Roi (40 ft. Gillnetter: Shaft Power vs. Speed) Sh haft Power (HP) Knots

51 A/C Power from Inverters Harmonic Distortion Square Wave Inverter Shore Power

52 A/C Power from Inverters True SineWave Inverters Sine Wave Inverter Shore Power

53 HIGH EFFICIENCY LIGHTING Fluorescent Bulbs and Ballast T12 Bulbs and Ballast phased out Match Ballast to Bulbs Specs for Bulbs and Ballast LED New Technology Life and Lumen output improved Cost decreasing Ensure quality LED used Thermal Management of LED

54 ENERGY STAR LABEL ENERGY STAR LABEL REQUIREMENTS Must be a good investment Non proprietary Must deliver same features and performance Energy savings and performance tested and verified