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ENERGY FLOW STREAMS IN THE MARINE STEAM PLANT DURING THE MAIN
PROPULSION PROPELLER SPEED VARIATION

PhD Student Eng. Igor Poljak1, PhD. Vedran Mrzljak2, PhD. Josip Orovic3,
����������� 51221 Kostrena1, Faculty of Engineering, University of Rijeka, Vukovarska 58, 51000 Rijeka2,
University of Zadar, Maritime Department, ����������������������, 23000 Zadar3, Croatia
E-mail: [email protected], [email protected], [email protected]

Abstract: For the analyzed LNG carrier with Rankine regenerative feed water cycle, energy analysis is presented. The intention was to
determine auxiliary flow streams from the useful ones. Auxiliary energy flow supports plant operation on the one side, but reduces overall
efficiency on the other. Steam generators energy streams are divided into two major groups, for the main and auxiliary stream consumers.
The steam system test was performed by varying main propulsion shaft revolutions. The required thermodynamic data are collected at
various steam system locations. For considered plant energy flow streams components are explained and analyzed. In this paper the
recommendations for possible energy savings for the mentioned propulsion plant are proposed.
Keywords: MARINE STEAM PLANT, MACHINERY, ENERGY FLOW, ENERGY SAVING

1. Introduction
Table 1. Marine steam plant chain indexes
Due to interpretation variability of power and mass flow of the 1 – Main boiler 13 – Deaerator
superheated Rankine cycle, it has risen necessity for 2 – High pressure turbine 14 – Feed water pump
clarifying energy motion inside the marine steam plant at LNG 3 – Low pressure turbine 15 – Feed water pump turbine
carrier. 4 – Turbo generator No1 16 – High pressure feed water
Although stationary steam power plants were wellbeing heater
elaborated by many authors, marine steam plants have not been 5 – Turbo generator No2 17 – De super heater
researched in that way yet. 6 – Main condenser 18 – Water heater
7 – Main condenser cooling sea 19 – LNG heater
water pump
In the context of electricity production, auxiliary load is the load 8 – Condensate pump 20 – Fuel oil heater
or device which consumes electricity while contributing to the 9 – Fresh water generator 21 – Contaminated service heaters
process of electricity generation or plant operation. Hence, this does 10 – Gland steam cooler 22 – Contaminated service cooler
not add to the total plant yield, but reduces the gross yield by a 11 – Low pressure feed water 23 – Condensate cooler
considerable amount. Thus, auxiliary load is the in-facility electrical heater
load which needs to be minimized [1], [2]. 12 – Auxiliary condensate pump
In marine power plant, the main auxiliary loads include: motors
used to run various service pumps which support plant operation, 2. Numerical model
fans for the boilers, turbine turning gear in port, electric pre-heaters,
etc. In addition to that, instrumentation, controls, computers, valve Elaborated power plant uses regenerative feed water cycle in
actuators, air compressors and lighting within the power plant also order to increase cycle efficiency. The feed water group will not be
add on to the auxiliary load. considered in this study. Plant flows are divided into two main
stream groups from the main boilers (plant consists of two identical
Electrical power which is generated on board the vessel for steam boilers): superheated and the de superheated streams.
supporting plant operation is gained from turbo generator units. Superheated stream may be divided into four sub streams: steam
Beside to auxiliary load, LNG carrier consumes steam, which is flow to the main turbine, steam flow to turbo generators No1 and
used for lube oil heaters, fuel oil heaters, waste oil tank heaters, No2 and steam flow to feed pump steam turbine. There is one
accommodation services heaters, etc. This amount of steam which additional superheated sub stream which relates to the losses and is
is taken from the boiler contributes to efficiency degradation of the noted as an additional superheated sub stream. The stream flows
total plant cycle. from the main boilers carry energy and mass notations. De
Considered marine steam plant overview is given in Fig.1. superheated steam stream flow to the service consumers is noted in
Explanation of all symbols from Fig.1 is presented in Table 1. the opposite direction, as presented in Fig.2.

Fig.1. Marine steam plant overview Fig.2. Stream flows to and after main boilers

131
3. Thermodynamic analysis - Main turbine:

Pressure, temperature and power are measured with standard � MT � hi ,MT


m
plant measuring equipment, which is displayed in Table 2. E� MT � �100[%] (4)
� ALL
Table 2. Marine steam plant measuring equipment
- Turbo generator and feed pump - Turbo generator No1 and No2:
steam turbine inlet steam pressure
- Main propulsion turbine inlet Pressure transmitter Yamatake � TG1 � hi ,TG1
m
steam pressure 960A [3] E� TG1 � � 100[%] (5)
- Main boiler de superheating outlet � ALL
steam pressure
- Turbo generator and feed pump � TG 2 � hi ,TG 2
m
steam turbine inlet steam
Temperature sensor MBT5113 E� TG 2 � �100[%] (6)
temperature � ALL
[4]
- Main propulsion turbine inlet
steam temperature - Feed pump steam turbine:
- Main boiler de superheating steam Thermocouple mV/I conversion
outlet temperature module J-STP 90/95 [5]
- Main propulsion turbine shaft Kyma shaft power meter, Model
� FP � hi , FP
m
E� FP � � 100[%] (7)
power KPM-PFS [6] � ALL
Generator protection and power
- Turbo generators power management unit HIMAP-BC
[7]
- Service:

Thermodynamic results were obtained from the measured data at � SE � hi , SE


m
E� SE � � 100[%] (8)
various locations in the engine room. Individual stream flows to � ALL
dedicated direction is calculated according to [8], [9].
- Losses:
In the steady state process the mass balance of control volume is
calculated according to: � LO � hi , LO
m
E� LO � � 100[%] (9)
�i � � m
�m �o (1) � ALL
IN OUT

4. Analysis and discussion


The energy balance of the control volume is presented as:
The engine run test was made after cargo loading operation.
Steam energy stream flows during variation of revolutions at the
� E� i � Q� � � E� o � W� (2)
IN OUT main propulsion shaft are presented in the Table 4.

Table 3. specifies energy and mass stream flow calculation Table 4. Energy flow streams under speed variation of the main
procedure for the steam plant components observed in this analysis. propulsion shaft
Main Main Turbo Turbo Feed Service Losses
Table 3. Mass and energy stream flow calculation routines shaft turbine generator generator pump
RPM No1 No2
Mass flow Energy flow
(min-1) (kW) (kW) (kW) (kW) (kW) (kW)
� TG1 � m
m � TURBO GEN . E� TG1 � (m� TG1 � hi )TURBO GEN .
NO1 NO1 25.58 3606 4389 4389 3035 24305 223
34.33 9060 4424 4424 3079 22431 240
� TG 2 � m
m � TURBO GEN . NO 2 E� TG 2 � (m� TG 2 � hi )TURBO GEN . NO 2 41.78 15645 4302 4302 3039 14242 225
53.50 33082 4470 4470 3205 9707 289
m� FP � m� FEED PUMP E� FP � ( m� FP � hi ) FEED PUMP 56.65 27124 3779 3779 3143 12230 266
� MT � m 61.45 35697 3877 3877 2994 10782 300
m � MAIN TURBINE E� MT � ( m
� MT � hi ) MAIN TURBINE 62.52 35474 3782 3782 2989 10881 298
� SE � m 63.55 38090 3928 3928 3032 11218 316
m � SERVICE STEAM E� SE � ( m� SE � hi ) SERVICE STEAM 65.10 41022 3626 3626 3063 11524 330
66.08 42496 3663 3663 3092 11909 342
m� LO � m� LOSSES E� LO � (m� LO � hi ) LOSSES 67.68 45808 3562 3562 3146 12440 360
68.66 47362 3607 3607 3149 10914 359
Specific enthalpy of every steam flow was calculated by using 69.49 48755 3595 3595 3177 11258 368
measured pressures and temperatures. 70.37 50270 3599 3599 3198 11278 377
71.03 50832 3619 3619 3206 11187 379
Cumulative energy flow from main boilers to all observed steam 73.09 56002 3669 3669 3283 11760 408
plant components can be defined with: 74.59 62370 3767 3767 3314 8495 422
76.56 67454 3883 3883 3388 8660 449
78.41 73766 3926 3926 3472 8580 482
� ALL � m� MT � hi ,MT � 2 � m� TG � hi ,TG � m� FP � hi , FP � 79.46 79287 4199 4199 3457 2620 476
(3)
� m� SE � hi ,SE � m LO � hi , LO 80.44 82766 4465 4465 3509 2704 495
81.49 85339 4156 4156 3488 382 491
82.88 90640 4193 4193 3557 369 518
It is important to emphasize that both turbo generators have 83.00 91766 4250 4250 3574 371 525
identical mass flows and identical inlet pressures and temperatures
(consequently identical inlet specific enthalpies). The energy stream flow ratio of the specified stream flows, to
observed machineries or systems, according to the previously
Ratio of cumulative energy flow stream distributed to the explained calculation procedure is presented in the Table 5.
observed components is defined by the equations:

132
Table 5. Energy ratios for flow streams under speed variation of the methane belongs into group of greenhouse gasses. Sankey diagram
main propulsion shaft which presents this operational period, during main propulsion shaft
Main Main Turbo Turbo Feed Service Losses speed of 25 min-1 is presented in Fig.4.
shaft turbine generator generator pump
RPM No1 No2

(min-1) (%) (%) (%) (%) (%) (%)


25.58 9.02 10.99 10.99 7.60 60.84 0.56
34.33 20.75 10.13 10.13 7.05 51.38 0.55
41.78 37.47 10.30 10.30 7.28 34.11 0.54
53.50 59.91 8.09 8.09 5.80 17.58 0.52
56.65 53.90 7.51 7.51 6.25 24.30 0.53
61.45 62.05 6.74 6.74 5.20 18.74 0.52
62.52 62.01 6.61 6.61 5.22 19.02 0.52
63.55 62.95 6.49 6.49 5.01 18.54 0.52
65.10 64.92 5.74 5.74 4.85 18.24 0.52
66.08 65.21 5.62 5.62 4.74 18.28 0.52
67.68 66.51 5.17 5.17 4.57 18.06 0.52
68.66 68.64 5.23 5.23 4.56 15.82 0.52
69.49 68.91 5.08 5.08 4.49 15.91 0.52
70.37 69.51 4.98 4.98 4.42 15.59 0.52
71.03 69.78 4.97 4.97 4.40 15.36 0.52
73.09 71.08 4.66 4.66 4.17 14.92 0.52
74.59 75.94 4.59 4.59 4.03 10.34 0.51
76.56 76.90 4.43 4.43 3.86 9.87 0.51
78.41 78.35 4.17 4.17 3.69 9.11 0.51
79.46 84.13 4.46 4.46 3.67 2.78 0.50
80.44 84.11 4.54 4.54 3.57 2.75 0.50
81.49 87.07 4.24 4.24 3.56 0.39 0.50
82.88 87.60 4.05 4.05 3.44 0.36 0.50 Fig.4. Energy ratio in (%) at the main propulsion shaft speed of
83.00 87.62 4.06 4.06 3.41 0.35 0.50 25 min-1

Presentation of main and auxiliary steam energy flows with Higher relative energy stream flow consumption of the feed pump
variations of main propulsion shaft speed is given in Fig.3. Only steam turbine, Fig.4, occurs due to fact that feed pump is recycling
flow which is related to the ship propulsion is main (useful) flow. certain amount of the water at low plant loads in order to protect
For the observed ship steam plant, main energy flow is only one - itself from the cavitation which will be caused by water overheating
energy flow to the main turbine. Other observed energy flows are through the pump stages at reduced flow. Turbo generator higher
considered as auxiliary flows. energy consumption in the lower propulsion shaft operating zone is
caused by the bow thruster run and related electrical consumption.

Conducted analysis shows that 12.38% of the cumulative energy


ratio goes for auxiliary requirements at main propulsion shaft speed
of 83 min-1, Fig.5. The steam propulsion system load is directly
proportional to main shaft speed, so at the highest observed steam
system load the majority of energy flow from steam generators goes
to the main turbine.
It may be seen that feed pump steam turbine power consumption
at 83 min-1 is 3.41%, what is lower in comparison with the similar
auxiliary steam turbines in stationary steam plants for the rated
loads. The main difference is lower pumping pressure as marine
boiler MB-4-KS is designed to operate at steam pressure of 6 MPa,
in that respect pumping power is lower than, for example, of a
boiler which is operating at 16 MPa.
Considering the overall developed power, steam turbine for a
feed pump drive in this mode (83 min-1) is fed with a greater energy
flow than required. The reason for that fact can be found in
deaerator operation. From the observed steam system, steam after
the feed pump turbine is drained to the deaerator. At the highest
steam system operating load, calculated energy flow ratio to the
feed pump steam turbine is not in function to produce high power of
Fig.3. Energy ratio at various main propulsion shaft speeds the turbine than that to ensure smooth deaerator operation.
At the beginning of manoeuvring mode, 25 to 41 min-1, When compared energy ratios at the main propulsion shaft speed
dominating energy stream flows goes to the services, Table 5 and of 25 min-1 and 83 min-1 it is obvious from Fig.4 and Fig.5 that
Fig.3. This effect can be clearly explained. After loading operation, energy flow ratio, which is leading to both turbo generators and
cargo tank pressure is maintained with extra combusting inside the feed pump steam turbine decreases as steam system load increases.
main boilers. Steam excess which cannot be used for the auxiliary On the other side, the energy flow ratio of the main turbine has the
turbines or the main turbine drive is then dumped into the main opposite pattern of behavior in comparison with the turbo
condenser. Steam is fed into main boilers internal de super heater, generators and feed pump steam turbine. Energy flow ratio of the
which is located in the steam drum and there is cooled from ~ 500 main turbine increases during increase in steam system load.
°C to 300 °C from where it goes to service line, back to the main Finally, it is interesting to mention that steam system losses
condenser via dump system. The only benefit of such action is to energy ratio decreases from the lowest to the highest observed main
avoid air pollution with releasing methane to the atmosphere, since propulsion shaft speeds.

133
Nomenclature
Symbols Subscripts

m� mass flow rate (kg/s) MT main turbine


E� energy flow rate (kW) TG turbo generator
h specific enthalpy (kJ/kg) FP feed pump
Q� heat power (kW) SE service
W� mechanical power (kW) LO losses
i inlet
o outlet

6. Literature
[1] Asai, Akihisu: Available and Emerging Technology for
Reducing Greenhouse gas emissions from coal fired electricity
generation units, US Environment Protection Agency, October
2010; 47 (2): 10-14.
[2] Pearson, A.: Parasitic loads, ASHRAE Journal, September
2012.

Fig.5. Energy ratio in (%) at the main propulsion shaft speed of [3] http://www.industriascontrolpro.com/fichat/SS2-DST400-
83 min-1 0100.pdf (last visited 08.01.2017.)
[4] http://sensors.danfoss.com/temperature-sensors/mbt5113/#/
When comparing auxiliary with the main turbine energy flows (last visited 08.01.2017.)
for the observed steam system, it is interesting to present ratio
according to Table 4. Values from Table 4 for all auxiliary energy [5] http://www.azbil.com/products/factory/download/catalog-
flows are summarized and divided by the energy flow to the main spec/SS2-2330-0250-02.pdf (last visited 08.01.2017.)
turbine, at each observed main propulsion shaft speed. Fig. 6 [6] http://cn.dan-marine.com/uploadfiles/2011112919581355.pdf
presents that this ratio constantly decreases from 1008% at the main (last visited 08.01.2017.)
shaft speed of 25 min-1 to the 14% at the main shaft speed of 83
min-1. [7] http://www.terasaki.com.sg/images/HS21.pdf
(last visited 08.01.2017.)
[8] Moran, M. J., Shapiro, H. N.: Fundamentals of engineering
thermodynamics, 6th edition, John Wiley & Sons, Hoboken, NJ,
2008.
[9] Cengel Y.A., Boles M.A.: Thermodynamics an engineering
approach, 8th edition, McGraw-Hill Education, 2015.

Fig.6. Auxiliary requirement vs main turbine ratio for energy


stream flows

5. Conclusion
Described marine steam plant generates more auxiliary energy
flows at lower main propulsion shaft speeds than on the higher, so
the efficiency of the plant at lower operation speeds will be lower.
As for recommendation, reducing of auxiliary flow may be
achieved with higher speed of the LNG carrier and one turbo
generator operation after manoeuvring zone. Moreover, the steam
driven feed pump turbine has to be changed with electrically driven
pump, what will act beneficially to turbo generator specific steam
consumption.
Additionally, the high rate feed pump should be changed to a
lower rate feed pump in port and during manoeuvring zone as to
avoid recycling of feed water, what will cause decreased auxiliary
load consumption either steam or electrical power.
Further studies should include the profitability of installation of
variable speed driven pump electro motors, which could further
decrease auxiliary power consumption on given example.

134

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