The International Maritime Organization (IMO) is tightening efficiency requirements for CO₂ emissions from existing vessels, while onboard pumps often run for hours and consume vast amounts of energy. Conventional optimization measures are no longer sufficient. With the data-driven Pump Energy Saving System developed by the mechanical engineering and flow management specialist BESI Marine Systems in collaboration with EXOR, it is possible to reduce both energy consumption and wear while meeting stringent security and sustainability requirements.
The challenge: Ship pumps consume excessive energy and are prone to wear
The maritime industry accounts for almost three percent of global CO₂ emissions. By comparison, Germany’s share is slightly above 1.5 percent. This clearly shows that the sector is under significant pressure to improve energy efficiency and sustainability. For this reason, the International Maritime Organization (IMO) introduced the Energy Efficiency Existing Ship Index (EEXI), a regulation that obliges shipping companies to reduce CO₂ emissions on an annual basis.
Pumps as key components in ship operations
Simple technical measures such as optimized propellers or new bow designs are no longer enough to achieve meaningful improvements. Shipping companies are therefore turning their attention to technical operations. Pumps are among the most critical components, responsible for moving large volumes of liquid. This includes ballast water for stabilization, cooling water, fuel, and cargo.
They operate for many hours and are subject to significant wear. From both an ecological and an economic perspective, reducing energy consumption and mechanical abrasion is essential. Maintenance is also required at regular intervals, regardless of the actual load on each pump.
Data access as a key obstacle
A major challenge in optimization is limited access to the required data. Although ships are controlled by computerized systems, they are isolated due to stringent cybersecurity requirements. One crucial requirement is that operational data must be collected and securely processed locally. Another factor is the typically poor or unavailable internet connectivity at sea, which is often limited to low-bandwidth satellite links. These conditions make the implementation of modern IoT applications particularly challenging.
The challenges at a glance
- High share of global CO₂ emissions from the shipping industry
- Traditional measures are no longer sufficient
- Data access and cybersecurity hinder IoT solutions
- Limited internet connectivity at sea
The solution: A secure IoT application for ships
Data acquisition and secure storage
The system focuses on data acquisition and processing. All process and control data from the pumps are collected in the programmable logic controller (PLC). Through serial interfaces, this data is transferred to EXOR hardware and stored there.
Direct external access is not possible, as this would conflict with the strict security requirements of maritime systems. Instead, the data is stored locally and then manually exported by the ship’s crew using USB drives.
While this process may seem outdated, it meets essential requirements for data integrity and sovereignty. The systems remain protected from cyberattacks, while the necessary operational information can be analyzed onshore.
For internal evaluations, the stored log files are processed in Excel, where the data can be transformed into clear and illustrative charts. For more advanced analysis, specialized software tools such as MATLAB can be used. The collected data thus supports both documentation of energy savings and model development for further system optimization.
Use of X Platform and JMobile
EXOR’s X Platform is an integrated solution for industrial automation with the following features.
- It combines hardware, software and (when possible and permitted) cloud access into a single system that allows the control of machines and equipment.
- It enables secure remote access and offers functions for predictive maintenance, remote monitoring, energy management and predictive analytics.
- It works with hardware ranging from embedded systems to industrial PCs or HMIs (Human Machine Interfaces).
- The required software, called “JMobile,” supports communication across a wide range of protocols and devices. This makes it possible to collect data directly at the pump, visualize it graphically and compile it in reports.
The result: energy savings, safety and new perspectives
The example of BESI and EXOR demonstrates that IoT-based systems can be successfully implemented even under the demanding conditions of the shipping industry. The Pump Energy Saving System now provides a solution that enables energy savings and reduces wear. As a result, operating costs decrease and reliability increases. In addition, it meets all requirements for CO₂ emission reduction and sustainability.
The solution also offers new opportunities for future developments. By operating pumps at reduced speeds, wear is minimized, simplifying condition-based maintenance. Maintenance is no longer performed at fixed intervals but according to the actual condition of the equipment. Shipping companies receive early warnings of potential issues and can plan maintenance activities more efficiently.
Summary of results
- Energy savings through optimized pump control
- Reduced wear and lower maintenance costs
- Reliable protection against cyberattacks
- Condition-based maintenance instead of fixed intervals
