Energy-Efficient Cooling System Control in Ship Engine Rooms Using an Intelligent Integrated Automation, Control, and Monitoring System (IACMS)

This paper presents the results of research on an innovative, integrated IACMS (Intelligent Integrated Automation, Control, and Monitoring System), developed for energy-efficient operation of auxiliary machinery in ship engine rooms. The system, validated both in the laboratory and during full-scale operation on the MF Skania Ro-Pax ferry, integrates process monitoring, diagnostics, predictive maintenance, and intelligent energy optimization within a unified control architecture. This approach enables a significant reduction in electricity consumption while maintaining thermal safety and operational reliability. Laboratory tests focused on a pump cooling system with PLC and frequency converter control, achieving a 90.5% reduction in energy consumption compared to conventional constant-speed operation. During full-scale validation, the IACMS managed the seawater pump via adaptive frequency control (30–60 Hz). Two consecutive voyages demonstrated energy savings of 84.6% and 86.0%, with a daily energy reduction of 0.84 MWh, resulting in a decrease of approximately 0.5 tons of CO2 emissions per day. Additionally, an observed reduction of about 6–7% in daily generator-set energy was recorded during the analyzed period; this vessel-level value is indicative, as the generator supplies multiple onboard consumers. All trials confirmed stable cooling system temperatures, and comprehensive diagnostics revealed no negative impact of inverter control on the technical condition of equipment. The findings indicate that IACMS is a universal and scalable tool for improving energy efficiency and enabling predictive maintenance in ship engine room auxiliary systems. The system was positively validated in commercial operation and certified by the Polish Register of Shipping, confirming its technological maturity and readiness for widespread adoption in the maritime industry. The results pave the way for further deployments of intelligent energy management solutions in shipping, supporting maritime decarbonization goals.