An Exploratory Study on the Working Principles of Energy Saving Devices (ESDs)

Symposium on Green Ship Technology (Greenship'2011) Wuxi, China, October 2011 An Exploratory Study on the Working Principles of Energy Saving Devices (ESDs) Jie Dang 1, Hao Chen 2, Guoxiang Dong 3, Auke van der Ploeg 1, Rink Hallmann 1 and Francesco Mauro 1 1 Maritime Research Institute Netherlands (MARIN), Wageningen, The Netherlands 2 Guangzhou Shipbuilding International (GSI), Guangzhou, China 3 Shanghai Ship and Shipping Research Institute (SSSRI), Shanghai, China ABSTRACT A new Joint Industry Project (JIP) has been initiated recently by MARIN, called ESD-JILI ( 机理 ), looking into the working principles and scale effects on Energy Saving Devices (ESDs). Three ESDs have been chosen for the investigations in the first phase. They were a preduct with a supporting stator in the duct, a pre-swirl stator with asymmetric blade design and Propeller Boss Cap Fins (PBCF). Measurements of forces and moments on all components of the ESDs have been carried out in selfpropulsion model tests with dedicated sensors. Particle Image Velocimetry (PIV) technique has been used in the investigation of the detailed flow around the ESDs. In order to investigate the scale effects in model tests, a fullscale wake field was approximated by a smart ship model. Computational Fluid Dynamics (CFD) calculations were carried out both for designing the smart ship model and also for the detailed flow around the ESDs. Some findings and fundamental issues on scale-effects of the ESDs are addressed in this paper. Keywords ESDs, Propulsion, Efficiency, Energy Saving, PIV 1 INTRODUCTION With the oil price skyrocketing and the implementation of EEDI and EEOI approaching, the issue of green ships is almost daily brought into discussions with operators, owners, builders, classifications, shipping and harbour regulators and governments. As one of the major driving forces on reducing bunker cost and pollution, energy saving issues have become important again recently. Both for new buildings and also for retro-fits, Energy Saving Devices (ESDs) are widely accepted as important measures to improve the ship s total propulsive efficiency. An ESD can be a pre-duct, a pre-swirl stator and fins located upstream of a propeller, or a post stator, a rudder bulb, rudder fins, a PBCF or a twisted rudder in the downstream. There are many types of ESDs. A review of the ESDs and the MARIN research activities in this field is given recently by Hooijmans et al (2010). Many new ideas and patents have been proposed in the last decades, which have been tested in the towing tanks around the world (Hansen 2011, Lee et al 1992, Mewis 2011, etc.). Several of the ideas have been fitted to real ships and tried at full scale. But very limited trial data are available in the public domain. According to a limited number of publications, the best achievement in improving efficiency by adding an ESD to an existing vessel is more than 10% according to the model tests. Feedbacks from full-scale sea trials have shown typically up to 5% improvement on total propulsive efficiency. These achievements are already very promising, although discrepancies between predictions and sea-trials are often seen. But until now, there is very limited information on why and how a specific ESD can improve the total propulsive efficiency of a vessel, except for the working principles described by the inventor himself. There is only a limited number of studies which provide an understanding of the working mechanism of the ESDs. Therefore in the past, many ESDs were designed by trial-and-error method and the designers had to hope that their designs would be proven in reality. In addition to these uncertainties, an ESD suffers often from strong scale effects. The achievement in full scale is often different from what is found in model scale. This makes the application of the ESDs at full scale sometimes questionable. Thanks to the rapid development of CFD, the working principle and the scale effects on ESDs are becoming clearer than before (Heinke 2011 and Çelik 2007). In addition, CFD provides guidance on ESD designs so that the performance of ESDs can be optimized even for fullscale conditions and flow separation, often found on misaligned ESDs, can be prevented (Zondervan et al 2011). In order to help the shipbuilding industry to understand the working principle of the ESDs and to develop a proper extrapolation method for the model test results, parallel to other projects on ESDs, MARIN recently initiated a new Joint Industry Project (JIP) called ESD-JILI with focus on

the working mechanism of a selection of ESDs. For the first phase of this project, only three types of ESDs have been investigated which are considered to be the most promising ESDs for full block merchant ships. They are, - a pre-duct with a supporting stator in the duct; - a pre-swirl stator with asymmetric blade design; - a PBCF. Investigations using four different techniques have been carried out, which include, - the force and moment measurements of all the components of the ESDs and the propeller; - the Particle Image Velocimetry (PIV) flow measurements around the ESDs; - the Smart Ship Model technique to simulate the full-scale wake; - CFD calculations (This will be published soon but will not be discussed in the present paper). We have chosen two oil tankers for the study in the first phase of the JIP. One of the ships is a 80,000DWT tanker. Only the studies of the ESDs, selected and fitted to this tanker, are presented and discussed in the present paper. 2.1 ESD Models and sensors Three ESDs have been designed for this vessel empirically by the participants of this JIP. Figure 2 shows some examples of the assembled ESD models. Figure 2 The pre-duct with a supporting stator (L) and the pre-swirl stator (R), painted black for PIV measurements. The photos in Figure 3 show part of the ESD models made of Nylon by rapid prototyping. The PBCF has a lower pitch angle than that of the propeller at the root. 2 TEST SETUPS AND CFD SIMULATIONS The subject vessel for the study is a 80,000DWT oil tanker developed by GSI and SSSRI by using CFD and model tests. The vessel had been optimized already for its overall powering performance without ESDs. The main dimensions of the vessel are listed in Table 1. Table 1 Main dimensions of the 80,000DWT oil tanker Length Breadth Draught Lpp B T design 224.90 32.26 12.20 m m m A large ship model has been made of wood with a scale ratio of 23.94. During the model tests, a bronze stock propeller No. 5880R has been used. The main parameters of the stock propeller in full scale are given in Table 2. Table 2 Main parameters of the stock propeller Diameter Pitch ratio Blade area ratio Number of blades D P0.7R/D AE/A0 Z 6.120 0.894 0.430 4 m Figure 3 The pre-duct (left) with a supporting stator (centre) and the PBCF (right). In order to measure the forces and moments during the resistance and propulsion tests on all components of the ESDs and also on the propeller, the pre-duct was equipped with two 1-component sensors to measure the longitudinal force (thrust or drag) on the duct. Also the stator longitudinal force (thrust or drag) and the stator torque were measured by a hollow shaft sensor at the stator hub which is coaxial with the propeller shaft. At the end of the propeller shaft and close to the propeller hub, the thrust and the torque of the propeller were measured simultaneously. Figure 4 shows the details of the sensors and their locations. The calculated wake fields for model- and full-scales are shown in Figure 1. No flow separation has been found. Figure 4 The sensors used to measure forces and moments. Figure 1 Comparison of calculated nominal wake field for model scale and full scale. (geosim geometrically similar) The PBCF was fitted to the end of the propeller shaft. There was no force sensor in between. The force and moment generated by the PBCF were measured together with the propeller by the propeller shaft sensor.

2.2 Particle Image Velocimetry (PIV) To investigate the flow details around the ESDs (in front of the ESDs, in the ESD and propeller planes, and behind the propeller and the PBCF, with or without working propeller), 3-D PIV has been used. The following figure shows the PIV system installed on the carriage of the Deep Water Towing Tank at MARIN. made only to the aftbody only. The first basis form makes the upper part of the gondola more slender, the second one makes the lower part of the gondola more slender, and the third one makes the buttock higher than the original hull form. The computed wake fields are compared to the full-scale wake field of the original hull. By making systematic variations with interpolation in the design space with the three basis hull forms, hundreds of CFD calculations have been carried out. Finally, the candidate shown in Figure 7 has been chosen as the smart ship model for the present study. Figure 5 The PIV system used in the towing tank of MARIN. The PIV system is a DANTEC system built specifically for MARIN where three windows are opened on a streamlined body, one for the laser sheet and the other two are for the cameras. The system is installed at the post side of the ship model. At a certain angle, the view of the cameras may be obstructed by the propeller or the ESDs. In order to measure the flow on the starboard side, reverse towing of the ship model has been used. In order to prevent reflection on the models, the stern of the ship model and all the ESDs, including the propeller, were painted black, as shown in the Figure 2. The water was seeded with polyamide particles of a mean diameter approximately 60 µm. The system was calibrated before the tests with a multi-level calibration target. Figure 6 shows the locations of the measured cross-section planes. Figure 7 Comparison of the smart ship model (red thin lines) to the original hull form (black thick lines), not to scale. Propeller plane ESD plane Figure 8 Comparison of computed full-scale wake of original hull form with that of the smart ship model, top: axial velocity, bottom: transverse velocity. propeller plane Figure 6 The PIV measurement plane locations. 2.3 Smart ship model A so-called smart ship model technique (Schuiling et al 2011) is used in the present studies. The smart ship model is in principle only a Wake Field Generator (WFG) so that a wake field similar to the full scale wake can be generated during model tests. The propulsion test results with a smart ship model is aimed at the force and moment measurements on the ESDs and the relative powering effect of the ESDs, but is not interpreted in an absolute sense. The details of the CFD used for the smart ship model design can be found in van der Ploeg et al (2000). In order to find the geometry of the smart ship model, three basis hull forms have been designed that are modifications of the original form. Changes have been duct plane Figure 9 Axial wakes, top: 0.7R and 0.5R on the propeller plane, bottom: 1.0R duct and 0.9R duct on the pre-duct plane. The wake fields at both the propeller plane and the ESD plane are plotted in Figure 8 and Figure 9, with

comparison to the full scale wake field calculated, where the circle with solid lines show the propeller disc and the dashed lines show the outer diameter of the pre-duct. It is seen that the full scale wake field is well approached by the smart ship model, except for the inner radii at 12 o clock position where the flow deficit is still higher than in full scale. The deviations are also slightly bigger in the lower part of the disk compared to the upper part, especially for the propeller. 3 FORCE AND MOMENT MEASUREMENTS In order to get reliable test results, all test runs have been carried out on one day with a well-controlled waiting time in between the measuring runs. The tests have been carried out by fitting ESDs one by one to the ship model, with some combined cases with the PBCF. The reference propulsion test wihtout ESD is used as the basis for the comparisons. 3.1 Resistance tests with ESDs It sometimes occurs that flow separation takes place at the stern during the model tests due to too low Reynolds number combined with a full block and poorly designed aftbody of a ship with small model size. When an ESD is fitted to those ship models, such as for the wake equalizing ducts (WED), it may change the local flow situation and reduce flow separation, resulting in a fictitious improvement of the powering performance of the vessel. But the CFD calculations, as shown in Figure 1, indicate that this will not take place for the present ship with the large model used here. In addition to the bare hull, resistance tests have been carried out for the model fitted with the ESDs. Table 3 shows the resistance changes by fitting the ESDs during the resistance tests. Table 3 Resistance with and without ESDs (tank values) no ESD pre-duct with stator pre-swirl stator Vs Rs Rs Rs T_ duct Rs Rs knots kn kn % kn kn % 12 797 800 0.41% -0.98 13 922 931 0.99% -0.97 14 1080 1077-0.25% -0.47 15 1274 1279 0.44% -0.24 1290 1.30% 16 1522 1514-0.48% -0.22 It is shown clearly in this table that the pre-swirl stator generates drag which acounts for about 1.3% of the total vessel resistance at 15 knots. This is expected since generating a swirl in the flow costs energy. The pre-duct generates drag too (see T_duct, which are all negative), although the drag on the duct is rather small (less than 0.1% of the total resistance Rs). It is believed to be mainly due to the friction drag on the wetted surface of the duct. But when comparing the total resistance Rs for the pre-duct with a supporting stator to that of the resistance without ESDs, some small increase or decrease on resistance (less than ±1%) is found. This suggests that in some conditions, the stator inside of the pre-duct may generate thrust. This suggests also that, instead of the assumed pre-swirl function, the stator in the duct may convert some rotational energy of the ship wake flow into net thrust (acting as a post-stator). The setting angles of the stator blades, the tranverse velocity of the ship s wake and the interaction with the duct can have strong effects on it. 3.2 Pre-duct with a supporting stator in the duct As can be seen in Figure 3, the stator blades are fixed to a stator hub (a bossing) which includes a small part of the gondola. The stator force and moment measured during the propulsion tests include also the forces acting on the hub. In order to obtain the blade forces, the forces on the hub have been subtracted from the measured forces found from the resistance tests by a dummy stator hub without blades. It should be pointed out that the interaction between the propeller and the stator hub is also included in the stator blade forces during the measurements. During the propulsion tests, both vessel speed variation tests (from 12 knots to 16 knots) and propeller load variation tests (at the design speed of 15 knots for different shaft RPMs) have been carried out. When analyzing the test data, it has been found that the forces on the ESDs are strongly dependent on the propeller thrust. After nondimensionalizing the measured thrust and torque on the ESDs by using the propeller shaft rotational rate and the propeller diameter in the same way as for the propeller thrust and torque coefficients, thrust and torque coefficients of the ESDs are obtained. Linear relations can be seen between the ESD thrust and the propeller thrust as given in Figure 10 for the original hull form. 0.05 0.04 0.03 0.02 0.01 0.00-0.01 Kt-Stator (ESD Pre-Duct with stator) Kt-Duct (ESD Pre-Duct with stator) Kt-Total (ESD Pre-Duct with stator) propeller thrust at full scale wake scaling 0.16 0.18 0.20 0.22 0.24 0.26 0.28 Propeller Thrust Coefficient Kt Figure 10 Measured ESD thrust coefficients original hull. All the points shown on Figure 10 are the mean values of the raw data sampled during the propulsion tests. The linearity of the relation is evident between the ESD thrust and the propeller thrust. There is some scatter for the stator thrust. It can be due to the subtraction of the dummy hub drag from the resistance test results where the effect of the propeller on the stator hub and the possible gap effects, between the stator hub and the hull and between the stator and propeller hubs, are not included. When matched with the open water characteristics of the propeller, the ESD thrust coefficients can also be expressed as a function of the propeller advance ratio as shown in Figure 11. As indications, also plotted in both Figure 10 and Figure 11 are the operational point of the propeller at 15 knots in model and full scales. For single screw vessels, the operational point of the propeller can be rather different for model scale and for full scale, depending on the wake propeller thrust at model scale

scaling factor (V A /V) s /(V A /V) m. For the present vessel, this factor has been chosen as 1.113 according to statistics. The test results for the original hull form leads to the following conclusions: - The pre-duct generates a thrust which is as high as about 8% of the propeller thrust at 15 knots. - Surprisingly, the supporting stator in the duct generates also a positive thrust (approximately 2% of the propeller thrust), implying that the stator does not generate pre-swirl to the propeller. Instead, it converts rotational energy from the wake of the hull into net thrust (including also interaction with the duct). - The pre-duct thrust decreases with the increase of the propeller advance ratio, similar to a conventional ducted propeller, implying a worse performance in full scale. - In contrast, the stator thrust increases with the increase of the propeller advance ratio, implying a better performance in full scale. 0.05 0.04 0.03 0.02 0.01 0.00-0.01 Atmodel scale J wake scaling Atfull scale J Kt-Stator (ESD Pre-Duct with stator) Kt-Duct (ESD Pre-Duct with stator) Kt-total (ESD Pre-Duct with stator) 0.40 0.45 0.50 0.55 0.60 0.65 0.70 Propeller Advance Coefficient J Figure 11 ESD thrust coeff. versus propeller J original hull. 0.03 0.02 0.01 0.00-0.01 Kt-Stator (ESD Pre-Duct with stator) Kt-Duct (ESD Pre-Duct with stator) Kt-Total (ESD Pre-Duct with stator) 0.16 0.18 0.20 0.22 0.24 0.26 0.28 Propeller Thrust Coefficient Kt Figure 12 Measured ESD thrust coefficients - smart ship model. When the same pre-duct with the same supporting stator in the duct is fitted behind the smart ship model during propulsion tests, the measured duct and stator thrusts were reduced dramatically, as shown in Figure 12. The duct generated still a positive thrust which is only about 2.5% of the propeller thrust at 15 knots, while the stator in the duct generates negligible positive thrust. This suggests that the scale effects from model scale to full scale, both for the present pre-duct and the supporting stator, are significant, especially for the pre-duct. 3.3 Pre-swirl stator With the same trend as that of the supporting stator in the pre-duct, the thrust of the pre-swirl stator increases also with increasing propeller advance ratio. But all the thrust measured on the pre-swirl stator for all the propulsion test runs with the original hull form showed negative values. This means that the pre-swirl stator generated drag, as shown in Figure 13. As one would expect, the energy cost to generate the preswirl flow to the propeller should be recovered by the propeller so that there are ideally no rotational losses in the slipstream of the propulsor and the rudder. 0.020 0.010 0.000-0.010 Kt-Stator (ESD Pre-Swirl stator) 0.16 0.18 0.20 0.22 0.24 0.26 0.28 0.30 Propeller Thrust Coefficient Kt Figure 13 Thrust on the pre-swirl stator original hull. When the pre-swirl stator was tested behind the smart ship model, the same trend with the same level of drag force on the stator has been measured as that behind the original hull form, which is plotted in Figure 14. This suggests that the present pre-swirl stator may be less sensitive to scale effects from model scale to full scale. 0.020 0.010 0.000-0.010 Kt-Stator (ESD Pre-Swirl stator) 0.16 0.18 0.20 0.22 0.24 0.26 0.28 0.30 Propeller Thrust Coefficient Kt Figure 14 Thrust on the pre-swirl stator smart ship model. 3.4 PBCF In order to understand the working mechanism of the PBCF, open water tests with reverse test setup have been carried out. A quasi-steady open water test technique was used so that a range of open water characteristics from J=0 to K T =0 can be obtained efficiently from only one test run. The test setup is shown in Figure 15. The MARIN open water test POD has a very slender body. Previous studies on reverse open water tests have shown only very small differences between the reverse open water test and the normal open water test. Due to the relative comparative nature of the present study, no correction has been made for the influence of the POD. The 5 open water tests consist of 1 test for the propeller with conventional cap and 4 tests with the PBCF at 4 different position angles as shown by the markers on the propeller hub in Figure 15. The 4 relative PBCF blades position angles have been 21, 24, 27 and 30 degrees,

defined between the trailing edge of the propeller blade at the root and the leading edge of the PBCF. All the tests have been carried out with a constant propeller shaft rotational rate of 900 RPM. total thrust and decreases the total torque on the propeller shaft. They are about KT=0.0017 and KQ=-0.00035 at J around 0.2. If this PBCF effect at low J values explains the effect of the PBCF in behind condition, it will have a contribution to the improvement of the total performance of the vessel by about 2% with the present PBCF design, which is by no means carefully designed for the present study. Optimizing the PBCF design may lead to higher gains. 0.006 PBCF setting angle 21 deg. PBCF setting angle 24 deg. PBCF setting angle 27 deg. PBCF setting angle 30 deg. 0.005 KT 0.004 0.003 Figure 15 Reverse open water test setup and position angles between the blades of the propeller and the PBCF. 0.002 The results show that the PBCF has hardly any effect on the total propeller open water efficiency around its mean operation condition of about J=0.5 for the present oil tanker. Only +0.47% (max.) relative improvement has been found at all 4 PBCF position angles. 0.000 0.8 With PBCF (setting angle 27 degrees) 0.8 PBCF setting angle 21 deg. PBCF setting angle 24 deg. PBCF setting angle 27 deg. PBCF setting angle 30 deg. 0.0003 0.0001-0.0001-0.0005 0.6 K T, 10KQ, η 0 0.0005 0.2 0.4 0.6 Propeller advance coefficient J -0.0003 Without PBCF 0.7 0.0 KQ One representative results for the PBCF position angle of 27 degrees is plotted in Figure 16. 0.001 0.0 0.5 0.2 0.4 0.6 Propeller advance coefficient J 0.8 Figure 17 Influence of PBCF on total thrust and torque. 0.4 4. PIV measurements 0.3 0.2 0.1 0 0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 Propeller Advance Coefficient J 0.8 0.9 1 Figure 16 Open water test results with and without PBCF It is indeed that the PBCF does have a strong influence on the total KT and KQ at lower J values where KT is increased and KQ is decreased a lot by fitting a PBCF. This influence should not be over-looked since the blade root of a propeller with PBCF is working in a more heavily loaded condition with lower inflow velocity (see Figure 1) than the mean velocity on the propeller disc in behind of a single-screw full-block vessel. When subtracting the open water results without PBCF from the 4 open water results with PBCF and plotting the differences, we obtain Figure 17. This figure shows, - At the operational condition (around J=0.5), the PBCF has very small effects on the propeller thrust (about KT 0.0005 to 0.001). It has almost no effect on the torque. - The effect of PBCF is not so sensitive to the position angle in the range from 24 to 30 degrees as tested. Only when the leading edge of the PBCF is very close to the trailing edge of the blade root on the pressure side (at 21 degrees), the effect of PBCF position becomes distinguishable. - At low J values, a clear effect of the PBCF on the thrust and torque can be seen. The PBCF increases the As described in Figure 6, the flow details on 8 vertical and transverse planes in the stern area of the vessel have been measured, with and without the working propeller and with and without the ESDs. For the plane BH behind the propeller, the unsteady flow has been measured by triggering the propeller blade angular positions, with and without the PBCF. A large amount of valuable data has thus been obtained, only limited results can be discussed in the scope of the present short paper. Left: without ESD, Right: the pre-duct with a supporting stator, Circle: the inner diameter of the pre-duct Figure 18 PIV measurements without working propeller, 15 knots, original hull form. Figure 18 shows the nominal wake field at planes PS2 (without ESD) and SB1 (with pre-duct and a supporting stator in the duct). For the present vessel, it is seen that the pre-duct has hardly any influence on the flow at the upstream of the duct when there is no working propeller. When there is a working propeller just downstream of the pre-duct, the suction effect of the propeller is clearly seen in the flow field just in front of the duct leading edge

(plane SB1, Figure 19), when compared to Figure 18. The figure on the right-hand side of Figure 18 shows that the pre-duct accelerates the flow further so that the wake peak at 12 o clock position becomes narrower. - with working propeller only, which is reduced by the pre-duct with stator and further reduced by the PBCF. The effect is also clear in the vorticity plots. The PBCF reduces the total strength of the vorticity and makes the flow rotation less concentrated. The axial and transverse velocities behind the PBCF are reduced significantly by the PBCF. This may suggest pressure increase at the end of the PBCF hub. 5 Extrapolation of powering tests with ESDs Left: without ESD, Right: pre-duct with supporting stator, Circles: duct/prop Figure 19 PIV measurements with working propeller, 15 knots, original hull form. (plane SB1, upstream of pre-duct) Extrapolating the powering model test results with ESDs to full scale remains a very challenge task. In the first phase of this JIP, we decided to use the MARIN standard method (Holtrop 2001) but taking into consideration of the findings discussed in the last sections as much as possible. 5.1 Extrapolation method During the extrapolation of the model test results to full scale, we treat the ESDs as part of the propulsor instead of appendages. Since the thrust of the ESDs have been measured during all the tests, the total thrust of the ESDs and the propeller are seen as the total thrust of a propulsor to this vessel. The following corrections to the MARIN standard 3-D extrapolation method has been proposed in order to take the ESDs into consideration. propeller where Tp is the propeller thrust, TESD is the total thrust of the ESD and TESD is the viscous correction to the ESD. pre-duct with a supporting stator + propeller When the thrust forces on the ESD (positive or negative) is taken into consideration in the extrapolation programme, the wake scaling effects found and discussed in Section 3.2 and 3.3 are automatically taken into account. The Reynolds effects on the ESD thrust (friction and pressure drags) have been taken into consideration by the viscous correction which is calculated according to, where the ITTC 1957 formula of the flat plate is used for the friction coefficients and the form factor k2 is empirically calculated as a function of the thickness to chord ratio as 2t/C. pre-duct with a supporting stator + propeller + PBCF Figure 20 PIV measurements at plane BH (averaged), 15 knots, left: velocity, right: vorticity, original hull form. Behind the working propeller, PIV measurements have been carried out with and without the ESDs, including the PBCF. Selected results are shown in Figure 20, both for the velocity field (on the left) and also for the vorticity field (on the right). The following observations are made from the measurements, - Comparing the vorticity with and without the ESD, it is clearly seen that there is vortex shedding on the portside, associated with the two stator blades which have larger angles of attack. - Comparing the velocity fields behind the propeller at the shaft, a strong swirl can be seen for the situation This extrapolation method has been used both for the model tests for the ship model with the original form, as well as for the smart ship model. As we have pointed out at the beginning of this paper, the smart ship model is used only for relative comparison. For the smart ship model test results, we have tuned the form factor 1+k and the correlation allowance CA so that the same level of the total resistance of the vessel has been reached. For the smart ship model, the wake scaling factor is set to 1. The parameters used in the calculations are listed in Table 4. Table 4 Extrapolation factors Original hull form Smart ship model 1+k 1.200 1.165 CA 0.00030 0.00036 (VA/V)s/(VA/V)m 1.113 1.000

When the correlation factors listed in Table 4 are used in the speed-power prediction for the basis cases without the ESDs, the same shaft power levels at the same vessel speed have been reached precisely, both for the original hull form and for the smart ship model. By using these two cases without ESDs as the basis for the relative comparisons, the following performance predictions and power savings have been obtained after fitting the ESDs. 5.2 Performance prediction The predicted shaft power levels based on the original hull form and on the smart ship model are shown in Figure 21 and Figure 22, respectively. Figure 21 Speed power predictions based on original hull. Figure 22 Speed power predictions based on smart ship model. It is seen that both model tests predict more than 4% energy saving when fitting the pre-swirl stator. The PBCF improves the performance by more than 2%, as expected in Section 3.4. The most energy saving comes from the pre-duct with a supporting stator in the duct, about 6%. Surprisingly, the pre-duct with a supporting stator performs also very well in the simulated full scale wake field, although the duct thrust is dramatically reduced. This can only be explained that the stator in the duct works also differently in the simulated full-scale wake. This will be made clear when the PIV measurements are carried out for the smart ship model. Some additional propulsion tests have also been carried out by combing the PBCF with the pre-swirl stator and the pre-duct with a supporting stator, respectively. In both cases, the total propulsive efficiency has been further improved. But the improvement is only approximately 1.0% at 15 knots. This can be understood from Figure 20. It should be pointed out that the thrust deduction behind the smart ship model with ESDs can be different from that behind the original ship model or from that without the ESDs, even if the comparison is in a relative sense. But this effect cannot be easily subtracted from the test results. It was decided to leave this out of the present paper. Further details are being investigated by using CFD calculations and will be published soon. 6 CONCLUSIONS The forces and moments on all the ESD components were measured during the model tests, the smart ship model successfully improved the similarity with the full-scale wake and the PIV measurement results provided insights into the flows about the ESDs. The present JIP studies on ESDs shed important light on the working principles of the ESDs and the scale effects, which will lead to an improved extrapolation of model tests with ESDs in the near future. The major findings of the present study are listed below. - The resistance test results on the original hull model fitted with ESDs show that both the pre-swirl stator and the pre-duct generate drag. But the supporting stator in the pre-duct converts the flow swirl from the hull into net positive thrust. - The propulsion test results on the original hull form fitted with the pre-duct with a supporting stator show that both the pre-duct and the supporting stator generate positive thrust. While the test results of the pre-swirl stator show clearly drag force on the stator. - Both the propulsion test results on the original hull model and on the smart ship model, fitted with ESDs, show clearly linear relations between the ESD thrust (or drag) and the propeller thrust. The thrust of the pre-duct increases with the increase of the propeller thrust, while the thrust of both stators decreases. This implies that the wake scaling from model to full scale will result in worse performance for the pre-duct and better performance for the stators. - The scale effects on the pre-duct used in the present study are significant. The duct thrust reduces dramatically from model scale to full scale. While the scale effects on the pre-swirl stator used in the present study are very limited. - The reverse open water tests with PBCF show that the PBCF has hardly any effect on the total propeller open water efficiency around its mean operation condition. But it has strong effects at low advance ratio J when the propeller is heavily loaded. This may explain why a considerable improvement on the total propulsive efficiency has been found by fitting a PBCF to the propeller in behind condition. - The results of the PIV measurements on the unsteady flows about the ESDs, triggered by the propeller angular position, clearly show the suction effect of the pre-duct; the vortex shedding from the stator blades; the propeller tip vortices and the strong hub vortex when there is no ESD. By fitting the pre-duct with a supporting stator, the hub vortex is reduced. When a

PBCF is fitted, the hub vortex in the slipstream of the propulsor (including ESDs) is completely eliminated. - The model test results show about 6% improvement by fitting the pre-duct with a supporting stator, about 4% improvement by fitting a pre-swirl stator and about 2% improvement by fitting only a PBCF to the propeller, on the total propulsive efficiency for a tanker in full scale. For the present study, the ESDs are by no means optimized. Further improvements are still possible. DISCLAIMER The present study is purely aimed at understanding the working principles of the selected ESDs in general. The ESDs used in the study may be, by coincidence, similar to other patented products. No designs with detailed geometry from any 3 rd party have been used in the present study. ACKNOWLEDGEMENT The authors are grateful for the valuable criticism, corrections and comments from Prof. Tom v. Terwisga of TU Delft and Mr. Jan Holtrop of MARIN on the draft of this paper. REFERENCES Çelik F. (2007). A Numerical Study for Effectiveness of a Wake Equalizing Duct Ocean Engineering, 34 pp 2138-2145. Hansen H. R., Dinham-Peren T. & Nojiri T. (2011). Model and Full Scale Evaluation of a Propeller Boss Cap Fins Device Fitted to an Aframax Tanker Proceedings of 2 nd International Symposium on Marine Propulsors, SMP 11. Hamburg, Germany. Heinke H-J. & Hellwig-Rieck K. (2011). Investigation of Scale Effects on Ships with a Wake Equalizing Duct or with Vortex Generator Fins, Proceedings of 2 nd International Symposium on Marine Propulsors, SMP 11. Hamburg, Germany. Holtrop J. (2001). Extrapolation of Propulsion Tests for Ships with Appendages and Complex Propulsors, Marine Technology. Vol 38, No 3, pp 145-157. Hooijmans, P., Holtrop J., Windt J., Bosschers J. & Zondervan G.-J. (2010). Refitting to Save Fuel and New Approaches in the Design of Newbuildings Proceedings of 11 th International Symposium on Practical Design of Ships and Other Structures. Rio de Janeiro, RJ, Brazil. Lee, J. T., Kim, M. C., Suh, J. C., Kim, S. H. & Choi, J. K. (1992). Development of a Preswirl Stator- Propeller System for Improvement of Propulsion Efficiency: a Symmetric Stator Propulsion System, Transaction of SNAK. No. 29(4), Busan, Korea. Mewis F. & Guiard Th. (2011). Mewis Duct - New Developments, Solutions and Conclusions, Proceedings of 2 nd International Symposium on Marine Propulsors, SMP 11. Hamburg, Germany. Ploeg A. van der, Hoekstra M. & Eça L. (2000). Combining Accuracy and Efficiency with Robustness in Ship Stern Flow Computation, Proceedings of the 23 rd Symposium on Naval hydrodynamics. Val de Reuil, France. Schuiling B., Lafeber F.-H., Ploeg A. van der & Wijngaarden E. van (2011). The Influence of the Wake Scale Effect on the Prediction of Hull Pressure due to Cavitating Propellers, Proceedings of 2 nd International Symposium on Marine Propulsors, SMP 11. Hamburg, Germany. Zondervan G.-J., Holtrop J., Windt J. & Terwisga T. (2011). On the Design and Analysis of Pre-Swirl Stators for Single and Twin Screw Ships, Proceedings of 2 nd International Symposium on Marine Propulsors, SMP 11. Hamburg, Germany.