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Concept Design of Hybrid Crane Vessel Feasibility Study of Utilizing Electric Energy Storage Technology

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Concept Design of Hybrid Crane Vessel Feasibility Study of Utilizing Electric Energy Storage Technology Concept Design of Hybrid Crane Vessel Feasibility study of utilizing electric energy storage technology Zelan Lyu Concept Design of Hybrid Crane Vessel Feasibility study of utilizing electric energy storage technology By Zelan Lyu in partial fulfilment of the requirements for the degree of Master of Science in Marine Engineering at the Delft University of Technology, to be defended publicly on Tuesday April 19th, 2016 at 14:00 PM. Report number: SDPO.016.009.m Supervisor: Ir. K. Visser TU Delft Thesis committee: Prof. Ir. J.J. Hopman, TU Delft Ir. K. Visser, TU Delft Dr. W.G. Haije, TU Delft Ing. F. van der Veen, HMC Heerema Ing. R. Wouts, HMC Heerema An electronic version of this thesis is available at http://repository.tudelft.nl/. Abstract Heerema Marine Contractors operates large crane vessels, which are exploited for installation works in the offshore oil and gas industry. The benchmark power system of these crane vessels is diesel electric meaning that the main engines are driving alternators for generating electric power. But due to spiky power demand and strict redundancy requirement in dynamic positioning mode of the crane vessel diesel engines on board are exposed to dynamic and extremely low load, which implies very high fuel consumption. Therefore, in order to solve the problem, it is envisaged to investigate the feasibility of hybridization of the benchmark power system, which leads to the research objective of this work: “Is it technical and economical feasible and advantageous of considering current electric energy storage (EES) technology for improving and optimizing the Thialf on board power generation and distribution system?” The objective is achieved by making concept design and deriving design criteria for the hybrid power system of the subject vessel by analyzing actual on board measurements. A model of the hybrid power system consists of a battery module, converter module, diesel engine module and control strategy module is created to verify and improve the design, which is used to answer the technical feasibility. An economic analysis is made to quantify fuel saving benefits and capital investment of hybrid system, which is used to answer the economic feasibility. EES serves three functions on board in the hybrid system: 1) Spinning reserve, replacing one running diesel engine in each engine room and secure power supply during diesel engine failure, 2) Typical peak shaving, absorbing load dynamics (spikes and valleys) so that operation of diesel engine is smoothed in typical dynamic positioning mode, 3) Demanding peak shaving, absorbing load dynamics in the most demanding crane operations. Results favor Lithium–Titanate battery, flywheel energy storage and supercapacitors in terms of technical feasibility. However, considering dimension and cost analysis as well, Lithium–Titanate battery is selected as the first priority of the hybrid system. The application of designed 446 kWh Lithium–Titanate battery in each engine room resulted in the following energy savings for the operation of subject vessel: 1) Fuel savings by eliminating diesel engine spinning reserve requirement is about 15% per year, which means an estimated yearly 900 k$ fuel saving, 2) Reduction of running hours of diesel engines is about 14,000 hours yearly, which means a saving on maintenance of approx. 300 k$ per year, 3) Furthermore, a fuel and maintenance saving potential by steadier diesel engine operation is showed, but this could not be verified in the model. Therefore, in terms of economic analysis, a yearly benefit of about 1.2 million $ is achieved and considering capital investment is roughly 6 million $ which means the payback period is about 5 years for the hybrid system. This project revealed some interesting topics for further research. In terms of diesel engine modelling, a model focus on modelling diesel engine dynamic transient operation instead of steady-state performance is of interest. And modelling the diesel engine performance in extremely low loads e.g., 10%-25% is also of interest, although diesel engine is not designed and built to run on such low loads. Recommendations on using a better battery model are also included. ii | Page Preface This master thesis report is the product of last twelve-months-long graduation project carried out at Delft University of Technology and Heerema Marine Contractors (Leiden). The idea of the topic origins from Heerema Marine Contractors Leiden office, Asset Management Department, Equipment Support Group. And finally, in this work, it proves that the idea is not only a pioneering and interesting one in oil & gas industry but also a smart and feasible one. I would very like to express my thanks to the following people: From TU Delft: • Klass Visser, who is my supervisor at TU, for his throughout guidance and supervision, valuable questions and excellent advices, which enlightened me throughout my graduation. • Hans Hopman, for his supervision, efficient feedback and interest he showed during the meetings and being the chairman of the committee. • Wim Haije, for being the committee member, very finely reviewing of my report and gave constructive criticism. • Peter de Vos, who introduced this project to me one year ago so that I didn’t miss the opportunity for such an interesting and challenging project. From Heerema Marine Contractors: • René Wouts, who is my daily supervisor at Heerema and has always been supportive and enthusiastic, for his attitude, knowledge and experience he shared with me, which set the example of a good engineer for me. • Fokke van der Veen, who is the leader of Equipment Support Group. His communication skills, encouragements and suggestions during my project were admirable. • All the colleges at Asset Management Department especially Equipment Support Group, this page is too short to name all of you, that made my time at Heerema a very pleasant one. Furthermore, I would like to thank: • Hong Zhou, Sotiris Kouroutzis and Rinze Geertsma for discussing diesel engine A4 model with me. • Valentin Muenzel, for discussing his Lithium-ion battery cycle life paper and model with me. • Louis-A. Dessaint and Olivier Tremblay for answering my questions on battery model in SimPowerSystems toolbox. Last but most important: I’d like to thank my parents and family for always believing and supporting me including paid a huge amount of tuition fee to support my master study at the Netherlands. Definitely, my friends, for sharing the joy, the interest and the beer with me as well. My girlfriend, for being my mirror, helping me and encouraging me all the time. Zelan Lyu Delft, April 2016 iii | Page “The main issue in this discipline is “system integration”: the integration of different equipment and disciplines to create well-functioning, efficient and cost- effective systems.” — Delft University of Technology Study Guide-Marine Technology-Design, Production and Operation-Marine Engineering iv | Page Contents 1. Introduction ............................................................................................................................... 1 1.1 Background..................................................................................................................... 1 1.2 Review of EES technology developments in marine sector .................................... 4 1.3 Synthesis......................................................................................................................... 7 2. Research objective .................................................................................................................... 8 2.1 Problem definition .......................................................................................................... 8 2.2 Research objective ...................................................................................................... 12 2.3 EES functions and benefits on Thialf application .................................................... 12 2.4 Hybrid system challenges and disadvantages ........................................................ 13 2.5 Main research question and outline of the thesis ................................................... 14 2.6 Research scope ........................................................................................................... 17 2.7 Synthesis....................................................................................................................... 18 3. Functional decomposition ....................................................................................................... 19 3.1 Thialf functions ............................................................................................................. 19 3.2 System & component .................................................................................................. 21 3.3 Energy flow diagram (EFD) ........................................................................................ 25 3.4 Synthesis....................................................................................................................... 27 4. Operational profile .................................................................................................................. 28 4.1 General .......................................................................................................................... 28 4.2 Load data analysis ....................................................................................................... 32 4.3 Fuel saving potentials ................................................................................................
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