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Chap - 2 Sample

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sufian
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CHAPTER- II: OPERATIONAL CHALLENGES OF CODAD BASED PROPULSION


SYSTEM FACED BY BN

Preamble.

0201. The CODAD (Combined Diesel and Diesel) propulsion system is extensively
utilized in the capital warships of the Bangladesh Navy's fleet. Integrating diesel
engines for both cruising and propulsion purposes, it offers a blend of efficiency and
operational capability. These CODAD systems, prevalent in most capital warships of
the BN, ensure operational flexibility and reliability, crucial for effective manoeuvring
in diverse maritime environments. However, despite its advantages, the CODAD
propulsion system faces challenges. Firstly, it may struggle to achieve the high
speeds necessary for certain naval operations, limiting the Navy's ability to respond
swiftly to emerging threats. Additionally, diesel engines operate most efficiently
within specific load ranges; prolonged operation below this range, such as during
low-speed cruising or idle conditions, can lead to carbon build-up and deposits.
These deposits adversely affect engine performance, resulting in decreased power
output, increased fuel consumption, and potential mechanical issues. Consequently,
fuel efficiency diminishes, leading to higher operational and repair costs. Lastly,
maintaining multiple diesel engines in a CODAD system demands comprehensive
maintenance procedures and skilled personnel, necessitating meticulous attention to
detail and investment in training and resources.

Overview of the Reasons for Integrating Combined Propulsion System.

0202. Selecting and integrating a combined propulsion system for warships involves a
detailed analysis of various performance curves and considerations to optimize efficiency,
power, and reliability. Among these curves, the resistance encountered by a ship is
influenced by factors such as speed, hull characteristics (including draft, beam, length, and
wetted surface area), and water temperature. As shown in Figure 2.1, the ship's speed
correlates with an increase in total hull resistance, depicted by a non-linear curve that
steepens at higher speeds. At lower speeds, viscous resistance dominates, whereas at
higher speeds, wave-making resistance becomes significant, causing a sharp rise in the total
resistance curve. This curve displays distinct "hump" and "hollow" features, typical in ship
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resistance profiles. Notably, after these features, doubling the ship's speed (e.g., from 15
knots to 30 knots) results in an eightfold increase in power demand due to the cubic
relationship between speed and required power. This highlights the significant increase in
power needed at higher speeds. The power required to propel a ship is calculated by
multiplying the total hull resistance by the ship's speed. To overcome this exponential
increase in resistance, propulsion systems like CODAD, CODOG, CODAG, and COGAG are
implemented. Moreover, integrating these systems involves balancing speed, fuel efficiency,
and fuel reserves to ensure safe and efficient navigation.

0203. In CODAD and CODAG configurations, a cruise diesel engine, and in COGAG
configuration, a cruise gas turbine can efficiently power a ship up to the hump point in the
resistance curve. Beyond this point, if the engine or gas turbine is operated with higher RPm
further, at certain point that single diesel engine or gas turbine per shaft might cross torque
limit (as shown in curve 2.4). On the contrary, operating a single engine or gas turbine per
shaft in low speed for prolonged period may degrade engine or Gas Turbine fuel efficiency
itself. Therefore, in capital warships, designers must consider redundancy, and must choose
propulsion configuration in such a way that prevents from affecting low load running effect
and be highly fuel efficient. To ensure this, either an additional diesel engine or a gas turbine
is engaged to encounter this increased resistance and maintain or boost speed through the
hollow point. In the CODOG arrangement, diesel engines provide power for cruising speeds,
and when higher speeds are necessary, the gas turbine is activated, allowing the diesel
engine to idle, or shut off.

Figure 2.1: Ship Resistance Curve


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Figure 2.2: Configuration Types: a. CODAD, b. CODAG, c. CODOG, d. COGAG

Load Limit

(a) (b)
Figure 2.3: Power Envelope Curve with SFC; (a) Marine Engine (b) Gas Turbine
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Figure2.4: CODOG arrangement selection Curve

Overview of Advantages and Disadvantages of CODAD Based Propulsion


System Faced by BN.

0205. Advantages of CODAD Based Propulsion System. The CODAD


(Combined Diesel and Diesel) propulsion system offers several advantages to BN,
making it a trusted choice for integrating BN vessels. Here are some key
advantages:

a. Greater Fuel Efficiency. CODAD systems are known for their fuel
efficiency. By integrating multiple diesel engines in per shaft, they can operate
at varying speeds while maintaining optimal fuel consumption rates. This
efficiency is crucial for long-range missions and extended patrols from BN
perspective, allowing vessels to maximize their operational range without
frequent refuelling. By comparing marine engine and gas turbine power
envelope curve with specific Fuel Consumption (sfc), it can be easily realized
that for generating 2.2-2.7 MW/h shaft power, a marine diesel engine
consumes approximately 191 g fuel on the contrary gas turbine consumes
close to 520 g fuel.
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b. Ensuring Redundancy. The redundancy inherent in CODAD


configurations enhances the reliability and resilience of the propulsion system.
In the event of engine failure or maintenance requirements, the vessel can
continue to operate using the remaining engines, ensuring mission continuity
and operational readiness.

c. Ensuring Operational Flexibility. CODAD systems provide


operational flexibility, allowing vessels to manoeuvre effectively in various
maritime environments. By adjusting the power output of individual engines,
ships can adapt to changing operational requirements, such as cruising, high-
speed transits, or stealthy approaches.

d. Cost-Effectiveness of Integration and Operation. Compared to


other propulsion systems, CODAD configurations are often more cost-
effective to procure, operate, and maintain. Diesel engines are widely
available, with established supply chains and maintenance infrastructure,
reducing acquisition and lifecycle costs for naval fleets.

0206. Disadvantages and Operational Challenges of CODAD Faced by BN


Navy. While the CODAD (Combined Diesel and Diesel) propulsion system offers
several advantages, it also has its share of disadvantages and causes operational
challenges to Bangladesh Navy:

a. Limited High-Speed Capability. CODAD systems of BN Ships


may face limitations in achieving high speeds required for certain naval
operations. The power output of diesel engines, while efficient at cruising
speeds, may not be sufficient for rapid acceleration or sustained high-speed
manoeuvres, impacting the vessel's ability to respond swiftly to emerging
threats or engage in high-speed pursuits. Moreover, for providing sustained
higher power output from diesel engine, size of diesel engine such as stroke
volume, piston size, crank shaft etc is to be increased which will lead to
compromise ship space. On the contrary, power to weight ratio of GT based
propulsion system is greater than diesel engine based propulsion systems
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and can be easily integrated in naval ships without compromising space.


From, figure 2.3, these phenomena can be easily understood.

b. Low Load Running Issues. Operating diesel engines at low


loads, such as during low-speed cruising or idle conditions, can lead to
inefficiencies and mechanical issues. In practical scenario, BN ships
manoeuvre with the speed of 6-10 knots during exercise to maintain the
formation. Also, while entering/leaving harbour, BN Ships has to operate the
engine for prolonged period. As a result, engines included in CODAD
propulsion system gets effected with Low Load Running Effects. This causes
problems like carbon build-up, piston ring sticky and worn out,
detonation/knocking, blow by, increased emissions, reduced fuel efficiency,
and potential engine damage, diminishing overall performance and increasing
maintenance requirements of engines.

c. Maintenance Complexity. Maintaining multiple diesel engines in


a CODAD system demands comprehensive maintenance procedures and
skilled personnel. Ensuring the optimal performance of each engine,
monitoring fuel consumption, and addressing potential mechanical issues
require meticulous attention to detail and investment in training and
resources. This complexity can increase operational costs and downtime for
maintenance activities.

d. Susceptible to More Acoustic Noise and Vibration. CODAD-


based propulsion systems in naval vessels causes increased acoustic noise
and vibration levels, particularly during high-speed operations. These higher
levels of noise and vibration can compromise the stealth capabilities of the
vessel, making it more detectable by adversaries, and potentially reducing its
effectiveness in covert operations, including underwater warfare where
minimizing acoustic signature is critical for evading detection by enemy sonar
systems. Additionally, the vibrations generated by CODAD propulsion
systems can impact the performance and reliability of sensitive onboard
equipment, posing challenges to maintaining operational readiness in
underwater warfare scenarios.
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e. Environmental Impact. While diesel engines are more fuel-efficient


than gas turbine engines, they still produce emissions that contribute to air
and water pollution. CODAD-powered vessels emit pollutants such as
nitrogen oxides (NOx), particulate matter (PM), and unburned hydrocarbons
(HC), which can have adverse effects on the environment and may
necessitate additional measures for compliance with emission regulations.

f. Operational Flexibility Constraints. CODAD systems may have


limited operational flexibility in certain scenarios, particularly during low-speed
manoeuvring or extended idle periods. This limitation can impact the vessel's
ability to maintain position in adverse weather conditions or conduct stealthy
operations, reducing overall mission effectiveness.

g. Increases Downtime and Reduces Operational Readiness.


CODAD-based propulsion systems increase operational challenges in terms
of man-hours and operational readiness due to their complex maintenance
requirements. The presence of multiple diesel engines necessitates extensive
upkeep, including regular inspections, servicing, and repairs, consuming
significant manpower and resources. This heightened maintenance demand
can result in longer downtime periods for vessels, reducing their availability for
operational tasks. Furthermore, coordinating maintenance schedules and
ensuring the availability of spare parts for multiple engines adds logistical
complexity, posing additional challenges to maintaining optimal operational
readiness levels.

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