Ship
A ship pump often runs for many hours on board and consumes a great deal of energy. With IoT, pumps are controlled based on data, so shipping companies save energy, reduce wear and document compliance with IMO CO₂ requirements.
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Data-driven ship pump control that saves energy
In the solution example, all process and control data from the pumps comes together in the PLC and is transferred via serial interfaces to EXOR hardware. The JMobile software of the X Platform collects the values directly at the pump, displays them graphically and summarises them in reports. Because of cybersecurity requirements on board and the poor internet connection at sea, there is no external access: the data is stored locally and the crew exports it via USB stick. Ashore, the log files are analysed in Excel or MATLAB.
The example comes from mechanical engineering and shipping. BESI Marine Systems, a specialist in flow management on ships, developed the Pump Energy Saving System PES together with EXOR. It controls pumps for ballast water, cooling water, fuel or cargo efficiently and provides the CO₂ evidence required by the Energy Efficiency Existing Ship Index (EEXI). Because the pumps run at reduced speeds, wear falls, and shipping companies can maintain them based on condition rather than at fixed intervals. In podcast episode 183, BESI and EXOR Deutschland explain how they divide the work between system integration and IoT infrastructure.
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Ship pumps and IoT: frequently asked questions
How do ship pumps help meet EEXI requirements?
Energy-efficient pump control reduces consumption on board and supplies the data for documentation. With the Energy Efficiency Existing Ship Index, the IMO has introduced binding rules that oblige shipping companies to cut their CO₂ emissions every year. Optimised propellers or new bow shapes are no longer enough. The Pump Energy Saving System from BESI and EXOR documents the savings achieved at the pumps.
Where can a ship save energy in technical operations?
Pumps are a major lever because they move large volumes of liquid and run for many hours. This ranges from ballast water for stability to cooling water, fuel and cargo. BESI Marine Systems controls these pumps based on data and at reduced speeds. This lowers energy consumption and mechanical wear at the same time, which cuts operating costs and increases reliability.
How is operating data captured securely on a ship?
The data is captured and stored locally on board, without direct external access. Ship systems are isolated because of strict cybersecurity requirements, and at sea there is usually no connection or only a weak satellite link. In the BESI and EXOR system, the crew exports the data via USB stick. This may seem old-fashioned, but it ensures tamper protection and data sovereignty while analysis takes place ashore.
Is demand-based control of ballast water pumps worthwhile?
Yes, because ballast water pumps are among the pumps that run for long periods on board and wear in the process. The Pump Energy Saving System PES from BESI Marine Systems controls them efficiently, like the other ship pumps. Until now, pumps were serviced at fixed intervals regardless of how heavily they were actually used. Reduced speeds lower wear, and maintenance can be planned according to condition.
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