calmac - excellence in technology and innovation submission

Saving fuel, costs and the environmentCategoryExcellence in Technology and Innovation

ENVIRONMENTAL KINDNESS AND MAJOR SHIPPING VESSELS MAY SEEM LIKE UNLIKELY BEDFELLOWS, BUT WE ARE COMMITTED TO TAKING STEPS TO IMPROVE OUR GREEN CREDENTIALS.”

“

PETER BRESLIN, TECHNICAL DIRECTOR, CALMAC

Caledonian MacBrayne

2 Excellence in Technology and Innovation Caledonian MacBrayne


4 5Excellence in Technology and Innovation Caledonian MacBrayne Caledonian MacBrayne Excellence in Technology and Innovation

Determined it should stay that way, 2015 saw us become the first UK ferry operator to introduce an innovative fuel monitoring system to our 10 major vessels.

The overriding aim of the six-phase initiative, known as Project Ecoship, is to reduce fuel consumption by a minimum of 2% – a target committed to in our Ship Energy Efficiency Management Plan (SEEMP) – and in doing so, reduce our greenhouse gas (GHG) emissions by 2%.

Achieve it and we will prevent approximately 1,885 tonnes of carbon dioxide alone from polluting the network. That’s the equivalent of 4,285,714 car miles or 645 tonnes of landfill waste.

Significantly for a publically-owned operator, we will also reduce fuel expenditure by an estimated £0.45m per year.

Unlike most other operators however, CalMac provides a lifeline service. The remote communities and economies of Scotland’s west coast rely on us to depart and arrive on time in order to get to work, education, healthcare, market and export.

Could we reduce fuel consumption without losing speed and jeopardising our timetables? That was the burning question that led, in early 2015, to CalMac specifying and procuring a cutting-edge fuel monitoring system – phases one and two of Project Ecoship.

Accurate dataWe were looking for a system that would accurately measure, monitor and report fuel consumption figures. A system that would enable us to establish baseline voyage-vessel figures, as mandated by the International Maritime Organisation’s (IMO) SEEMP, and seek ways to reduce them.

In June 2015 we got exactly that, appointing marine diesel power generation specialist Royston Limited to install its new second generation Enginei fuel management system on our 10 major fuel burning vessels.

SAVING FUEL, COSTS AND THE ENVIRONMENT

AS LIFELINE FERRY SERVICE PROVIDER FOR SCOTLAND’S WEST COAST ISLANDS AND PENINSULAS, CALMAC HAS THE PRIVILEGE OF SAILING THROUGH SOME OF THE MOST IDYLLIC AND UNSPOILT SCENERY IN THE WORLD.

LIKE MOST MARITIME OPERATORS, CALMAC’S GREATEST OPPORTUNITY TO REDUCE THE ENVIRONMENTAL IMPACT OF ITS ACTIVITIES IS TO REDUCE FUEL CONSUMPTION.

OVERVIEW THE BUSINESS CHALLENGE

“I warmly welcome the launch of Project Ecoship, which once again shows CalMac is at the forefront of ferry innovation.”

“If you reduce fuel, you reduce emissions – but you also potentially slow the vessel, delaying its arrival.”

“In digital operations, data is the new currency.”

DEREK MACKAY MSP, MINISTER FOR TRANSPORT AND ISLANDS

JOHN GRAY, PROJECT MANAGER, PROJECT ECOSHIP

OCEAN INDUSTRY PODIUM, NOR SHIPPING, 2015

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WITH A 31-STRONG FLEET, WE’RE THE UK’S LARGEST FERRY OPERATOR.

ALL 10 MAJOR FUEL BURNERS (VESSELS OVER 5,000 Gt) HAVE BEEN EQUIPPED WITH THE NEW SYSTEM.

SERVING 24 DIFFERENT ISLAND DESTINATIONS, WE PROVIDE OVER 130,000 SAILINGS ANNUALLY.

EVERY TONNE OF FUEL BURNED EMITS THREE TONNES OF CO2 INTO THE ATMOSPHERE.

CALMAC AT A GLANCE

MV Loch Seaforth sailing to Stornoway.

John Gray, Project Manager, Project Ecoship.


PERTH

NEWCASTLENEWCASTLE

CARLISLECARLISLE

EDINBURGHEDINBURGHGLASGOWGLASGOW

STIRLINGSTIRLING

PERTHPERTH

Dumfries

Newton StewartStranraer

Cairnryan

Girvan

Troon

Prestwick

Kilmarnock

Moffat

Jedburgh

Galashiels

Hawick

PeeblesLanark

FalkirkBalloch

GourockDunoon

CrianlarichCrieff

LochearnheadUpper Tyndrum

Amsterdam

FIRTH OF FORTH

FIRTH OF TAY

SO

LWA

Y F

IRTH

Wick

Scrabster

Durness

KinlochbervieTongue

John o’ Groats

Scourie

Lochinver

Brora

Dornoch

Golspie

Bonar Bridge

Lairg

Stornoway

Leverburgh

Lochmaddy

SOUTH UIST

BENBECULA

NORTH UIST

BERNERAY

HARRIS

LEWIS

BARRA

ERISKAY CANNA

RUM

MUCKEIGG

COLL

TIREE

IONA

COLONSAY

MULL

SKYE

JURA

ISLAY

GIGHA

KINTYRE ARRAN

BUTEGREAT

CUMBRAE

INVERNESSINVERNESS

ABERDEENABERDEEN

SCOTLANDSCOTLAND

ARDROSSAN

LARGS

WEMYSS BAY

AYR

KENNACRAIG

LISMORE

OBAN

Tarbert

Castlebay

Lochboisdale

Armadale

Sconser

Uig

RAASAY

ULLAPOOLDundonnell

Aultbea

Poolewe

Gairloch

Shieldaig

Lochcarron

KinlocheweAchnasheen

AlnessInvergordon

NairnForres

Buckie

Tain

Dingwall

Beauly

DrumnadrochitKyle of Lochalsh

Kyleakin

MALLAIGArisaig

Glenfinnan

Fort Augustus

Invergarry

SpeanBridge

Banff Fraserburgh

Peterhead

Kirkwall/Lerwick

Carrbridge

Kingussie

BraemarBallater

Dalwhinnie

Aviemore

Banchory

Stonehaven

Montrose

Berwickon Tweed

Dunbar

North Berwick

Anstruther

St Andrews

Arbroath

ForfarPitlochry

Dunkeld

Fort William

StrontianKilchoan

TobermoryLochaline

FishnishCraignure

Port Askaig

Port Ellen LochranzaTayinloan

Brodick

ColintraiveRhubodach

Tarbert PortavadieRothesay

Claonaig

Lower Tyndrum

Fionnphort

MV Caledonian Isles• Ardrossan to Brodick (Arran) MV Isle of Arran• Ardrossan to Brodick (Arran)• Ardrossan to Campbeltown MV Finlaggan• Kennacraig to Port Ellen (Islay)• Kennacraig to Port Askaig (Islay) MV Hebridean Isles• Kennacraig to Port Ellen (Islay)• Kennacraig to Port Askaig (Islay) MV Isle of Mull• Oban to Craignure (Mull) MV Clansman• Oban to Coll and Tiree• Oban to Castlebay (Barra)

and Lochboisdale (South Uist) MV Lord of the Isles• Oban to Coll and Tiree• Oban to Castlebay (Barra)

and Lochboisdale (South Uist)• Oban to Colonsay• Mallaig to Lochboisdale (South Uist) MV Loch Seaforth• Ullapool to Stornoway (Lewis)

MV Hebrides• Uig to Tarbert (Harris)• Uig to Lochmaddy (North Uist)

MV Isle of Lewis• Oban to Castlebay (Barra)


THE 10 MAJOR CALMAC VESSELS AND ROUTES

MV Isle of Lewis in Loch Broom.

MV Isle of Arran departing Kennacraig.



This is tracked against GPS data, voyage details and the ship’s operational mode. The real-time data is then relayed to touchscreen monitors in the engine control room and bridge, enabling Masters to see how small changes – for example, changing the propeller pitch settings – impact on fuel consumption and, just as importantly in our case, journey time.


THE £0.45M STATE-OF-THE ART ENGINEI SYSTEM USES FLOWMETERS AND SENSORS, EMBEDDED INTO THE MAIN ENGINES’ FUEL SUPPLY LINES, TO MONITOR FUEL CONSUMPTION.

THE TECHNOLOGY

INSTALLATIONBecause of the lifeline nature of our services, taking 10 vessels out of service for installation – phase three of Project Ecoship – just wasn’t an option. Instead, on eight out of 10 ships, we worked with Royston to install the system between the last sailing at night and the first service the next morning.

With some vessels requiring an hour’s priming before sailing, this meant working within a window of just six hours over four consecutive nights.

The remaining two ships had the system installed in dry dock, due to the complexity of the pipe work.

MASTERS TRAININGWith the system successfully installed, the ships’ Masters have all undergone training and begun trialling the new system – with interesting results.

Coriolis fuel flow meter on MV Hebridean Isles.Engine room on the MV Hebridean Isles showing fuel monitoring display.

Peter Breslin, Technical Director and John Gray, Project Manager, Project Ecoship.

MV Hebridean Isles sailing to Islay.



“By using industrial internet technologies (connected devices, embedded sensors and analytics technologies), we have the capability to create energy efficiency savings, reduce costs and improve environmental sustainability.”JOHN GRAY, PROJECT MANAGER, PROJECT ECOSHIP

Vessel Speed Profile: Oban to Castlebay [2nd December 2015]

Vessel Fuel Consumption Graph

MV Clansman: Vessel Speed Profile – Oban to Castlebay, 2nd December 2015

Vessel Data Export Report

Voyage ScreenMain Display

MV Finlaggan: Kennacraig/Port Askaig/Port Ellen

Engine Control Room - MV Finlaggan.



On the 22-year old MV Caledonian Isles for example, the first ship to receive the new system, we’ve discovered that balancing fuel flow by adjusting propeller pitch of the port and starboard engines reduces fuel consumption by one litre per minute. A saving that would enable us to reduce C02 emissions by well in excess of the minimum 2% target, and still make the timetable.

A similar saving has been achieved on the 19-year old MV Isle of Mull. This time, by reducing the propeller pitch from 100% to 90%, saving one litre of fuel per minute whilst still berthing on time.

The new system is also giving us an indication of what effect the tide and weather is having on fuel consumption. Up to two litres per minute can be added to a vessel’s fuel consumption when crossing the Minch in heavy seas and in areas like the Sound of Islay where there is a significant tidal effect.


WHILE BASELINE VOYAGE FUEL CONSUMPTION FIGURES HAVE STILL TO BE ESTABLISHED, EARLY DATA AND ANECDOTAL EVIDENCE IS HUGELY ENCOURAGING.

EARLY RESULTS

“The exciting bit is that this is just the start. With the ability to add in up to 20 different feeds, we plan to measure the impact of things like wind speed, strength of tide, stabiliser drag and sea depth on our fuel consumption.” JOHN GRAY, PROJECT MANAGER, PROJECT ECOSHIP

MARGINAL GAINSAdd up each of these marginal gains sailing after sailing, day after day, week after week and they will make a significant difference to our fuel consumption and GHGs.And those aren’t the potential only savings.

ADDITIONAL EFFICIENCIESOn MV Finlaggan we’ve connected torsion sensors to the system to measure how efficiently the engines run. A move that may negate the need to take ships out of service for two weeks’ maintenance each year if engines are found to be working at optimum efficiency.

We’re also trialling nitrous oxide emission measures on the same vessel.

MV Caledonian Isles sailing to Brodick, Arran.

MV Isle of Mull sailing to Craignure, Mull.

MV Finlaggan arriving at Port Askaig, Islay.

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Captain Barry Scott on the bridge of MV Finlaggan.

Excellence in Technology and Innovation Caledonian MacBrayne Caledonian MacBrayne Excellence in Technology and Innovation



THE US NAVY REPORTED THAT 7.5 MONTHS OF MARINE GROWTH ON A PROPELLER CAUSES UP TO 10% GREATER FUEL USAGE TO MAINTAIN THE SAME SHIP SPEED.

HULL COATINGSMarine growth is a common problem that upsets the hydrodynamics of the vessel causing ships to burn more fuel in order to maintain the same speed.

With the aid of the new system however, we will be able to evaluate different hull coatings to see which prevents marine build-up the longest, helping save fuel.

Where engine power is found to be dropping off due to marine growth, we’ll now be able to identify it more quickly. At which point it may prove more cost -efficient to send down divers to clean ships rather than wait until dry dock.

CONDITION-BASED MAINTENANCE Indeed, with the data now available to us, we may be able to move towards condition-based maintenance – a more cost-effective option than taking ships out of service.

DESIGN AND BUILDShip build itself may even change, with a new breed of greener ferries featuring more fuel efficient hull forms and design.


GOING FORWARD, THE INNOVATIVE SYSTEM WILL HELP REDUCE FUEL CONSUMPTION IN OTHER WAYS TOO.

THE WIDER POTENTIAL

“Currently, we’re looking at fuel consumption in terms of the efficiencies of the engine. Longer-term we hope to partner a university on a research project looking at energy consumption across the vessel as a whole.” JOHN GRAY, PROJECT MANAGER, PROJECT ECOSHIP

MV Clansman arriving at Castlebay, Barra.

MV Hebrides off Scalpay, Harris.



Ship-to-shore connectivity will enable:• Data to be shared with our

onshore technical team • System updates to be carried

out remotely • Best practice for reducing fuel

consumption to be shared amongst Masters.

With connectivity achieved, baselines established and trials completed, we can then embark on phases five and six: • Producing key performance

indicators and data reporting procedures

• Agreeing standard operating procedures for the most fuel efficient operation

• Applying those procedures across the whole fleet.


THE NEXT BIG CHALLENGE, PHASE FOUR, IS TO ACHIEVE SHIP-TO-SHORE CONNECTIVITY. NO SMALL TASK GIVEN THE REMOTENESS OF OUR NETWORK.

LOOKING AHEAD

“This state-of-the-art technology has the potential to have a significant impact on the fleet’s emissions, cutting its carbon footprint in some of Scotland’s most striking coastlines and sensitive marine environments.”

“Our commitment to the taxpayer and the environment has come together with Project Ecoship.”

DEREK MACKAY MSP, MINISTER FOR TRANSPORT AND ISLANDS

PETER BRESLIN, TECHNICAL DIRECTOR, CALMAC

At company level this will help us meet, and possibly exceed, the fuel efficiencies committed to in our SEEMP.

At national level it will contribute to the Scottish Government’s Climate Change Delivery Action Plan.

While at an international level, it will give us a strong head start with regards to legislation announced since embarking on Project Ecoship, requiring stricter monitoring, reporting and verification of ship borne CO2 emissions by 2018.

MV Lord of the Isles.

calmac - excellence in technology and innovation submission

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