Marine Fuel Flow Meter & Consumption Systems

Insatech Fuel Consumption System Front 1X1

Implementing the Insatech Marine Fuel Consumption System provides real-time, granular data on your ship's daily consumption. This critical insight empowers your crew to optimize sailing patterns and identify the most fuel-efficient operational mode, generating immediate cost savings (OPEX reduction). Furthermore, the system delivers a precise, data-driven basis to quantify the ROI of maintenance like hull cleaning, ensuring compliance with IMO CII regulations through verifiable performance improvements.

For sales or commercial inquiries please contact us at marine@insatech.com.

Contact us now

Optimizing Vessel Efficiency: The Low-Hanging Fruit

Operational efficiency is the cornerstone of profitability and sustainability in the maritime industry. Fuel costs constitute 50% - 70% of Operating Expenses (OPEX), making accurate fuel consumption measurement the most immediate and impactful area for improvement - the true "low-hanging fruit."

I. Fuel Consumption: The Basis for Profit & Compliance

Increasing crew awareness and knowledge of actual fuel consumption is key to validating improvement projects and new procedures. Our system provides the data required for:

Cost Reduction: Identify consumption fluctuations instantly to pinpoint and eliminate sources of waste.
Performance Benchmarking: Establish a precise baseline consumption to accurately gauge the benefit of performance-improving investments and maintenance (e.g., propeller cleaning).
Environmental Compliance: Documenting the vessel's primary source of emissions (fuel) via an automated system provides constant certainty of emission levels, critical for IMO CII and environmental reporting.

II. Why Marine Fuel Flow Meter Accuracy Matters (Coriolis vs. Volumetric)

Performance improvements directly correlate to fuel consumption reduction. Measurement accuracy is not negotiable when securing added profit from optimization.

Feature	Insatech Coriolis Mass Flow Meter System	Standard Volumetric Flow Meters
Accuracy	Better than $0.2\%$	Typically $0.5\%$
Measurement Type	Direct Mass Measurement (unaffected by temperature)	Volume-based, requires temperature-dependent conversion to calculate mass
Financial Impact	Highly precise data to secure savings.	Potential annual offset of up to $200$ on a typical vessel, due to slight misreads.

Financial Example: An offset of just 1% in measurement on a vessel consuming 100 tons per day for 200 days equals a loss of 200 tons of fuel per year - a significant uncaptured profit.

III. Know When You Make Money - And Make More!

Without high-accuracy measurement, it is truly difficult to quantify the ROI of procedural changes, new installations, or maintenance.

By installing our Fuel Consumption System, you immediately:

Eliminate Uncertainty: Move beyond less reliable data sources like noon reports or low-accuracy instrumentation to achieve timely, verifiable proof of fuel-saving projects.
Increase Crew Focus & Competitive Advantage: Free your crew from the operation and maintenance of complex instruments, allowing them to focus on their primary task: optimizing the ship's efficiency and increasing profits.

The Fuel Consumption System can be seamlessly upgraded to the comprehensive Performance Monitoring System for deeper analysis and operational intelligence.

The Marine Fuel Consumption System: Functionality & Data Leverage

The Insatech Fuel Consumption System utilizes high-accuracy mass flow meters to measure, collect, and process crucial fuel data. This automated process transforms raw consumption figures into actionable intelligence for your crew and shore office, driving operational efficiency, maintenance planning, and regulatory compliance.

I. How the System Works: Real-Time, Direct Measurement

The core principle involves the precise differential measurement of fuel flow to key consumers.

Technology: The system deploys Coriolis Mass Flow Meters strategically on the engine supply and return lines, or across other consumers (generators, boilers).
Measurement Principle: By measuring the flow of fuel before and after the engine/generator, the system calculates the exact consumption, free from temperature or volume fluctuations.
Direct Efficiency Calculation: Consumption data is correlated in real-time with external measurements like speed log and GPS signals to provide a direct calculation of fuel efficiency (e.g., grams/ton-mile).
Scalability: The system is customizable. Install flow meters per major consumer or a single set for the vessel's total consumption, depending on the required level of diagnostic insight.

II. Seamless Data Access & Shore Integration

We ensure your crew and headquarters have easy, reliable access to the measured data, regardless of connectivity.

Feature	Description	Key Benefit
Onboard Processing	Flow meter measurements are sent via Modbus signals to a central processing cabinet with built-in or remote operator interface.	Consumption is calculated, logged, and displayed locally for immediate crew awareness.
DataLink Option	Requires a dual-database setup (one onboard, one at headquarters) for automated data transfer.	Enables remote monitoring, centralized fleet analysis, and minimizes reporting effort.
Data Integrity	Data is securely stored onboard if the internet connection is temporarily lost and automatically sent once connectivity is restored.	Ensures continuous, complete data logging without gaps, crucial for regulatory documentation.

III. Making the Data Work for You: Key Applications

The processed consumption data is the foundation for a range of critical operational and commercial activities. Use this data to achieve a competitive edge:

Operational Optimization: Test and validate trim tools and other physical adjustments to find the most efficient operational setting.
Compliance & Management: Implement and maintain your SEEMP (Ship Energy Efficiency Management Plan) with verifiable data.
Performance Evaluation:
- Monitor and improve your current CII rating.
- Create KPI’s (Key Performance Indicators) for each voyage and vessel.
- Evaluate improvement projects (e.g., retrofits, hull coatings) before rolling them out fleet-wide.
Maintenance Planning: Monitor the ship’s consumption trend over time to proactively identify degradation (e.g., fouling, engine wear) and improve predictive maintenance scheduling.
Crew Empowerment: Provide the crew with instant, clear data insight to increase operational awareness and foster a culture of efficiency.

Upgrade Path: The Marine Fuel Consumption System is the core foundation and can be easily upgraded to the advanced Performance Monitoring System for deeper analytics.

Insatech Marine Fuel Consumption System Fuel Consumption In Detail 16 9

DataLink transfers data between fleet and shore

DataLink is an optional feature that automatically transfers the data collected on board to your own or a third-party database. This happens whenever an internet connection is established, and data validation ensures that no data is lost in the process. If no connection is available, the vessels database will just save the data locally, until the connection is reestablished.

Our systems collect a minimum of data which can be transferred on even the most challenging satellite internet connection furthermore DataLink checks the shore database for the latest data available and only transfers the new data further minimizing the amount of data that needs to be transferred.

Insatech Datalink Spacex Vbnb52j8trk Unsplash 16 9

Operation and User Experience

The Insatech Fuel Consumption System is designed for high reliability and minimal crew interaction, operating as a fully automated solution once installed.

I. Fully Automated, Low-Maintenance Operation

Zero Hands-On Requirement: The system is fully automated and requires no manual input or activation under normal operating conditions. Crew focus remains on vessel performance, not instrument maintenance.
Intuitive Operator Interface: The user interface is highly intuitive, providing a fast overview of all connected consumers. This ensures the crew quickly accesses the necessary information to take immediate action.

II. Flexible Display and Deployment

The system is versatile, allowing placement and data display to match specific operational requirements.

Panel Placement Flexibility: The operator panel can be strategically located in the Engine Room, Engine Control Room, or on the Bridge, depending on the crew's usage preference and workflow.
Scalable Data Display: The displayed data matches your system choice:
- Basic Systems: Clearly show the consumption of one or two primary consumer groups.
- Extensive Systems: Provide detailed consumption readings for a larger number of individual consumers and operational variables.

Benefit Focus: Ensures the right consumption data is available to the right personnel at the right time, minimizing training time and maximizing the likelihood of proactive operational optimization.

Main Engine Overview

The display of the main engine overview provides a total view of the main engine’s fuel consumption. A consumption trend line shows an accumulation of the most recent data. The setup is dependent on the number of installed meters.

Main Engine

If you want a more detailed view, simply select a main engine from the overview screen. From here it is possible to get the actual and total consumption of the given engine, as well as values for engine inlet and outlet such as mass flow, volume, density, temperature and total mass.

Auxiliary Engine Overview

From the Aux engine screen you get an overview of all your auxiliary engines’ consumption. As with the main engine overview, this also provides an easy to read display of consumptions, trends and engine loads.

Service Parameters

The service parameters displays raw data for each flow meter related to consumers. It shows the main menu data and provides the possibility for a manual totalizer. From here the alarm status screens are setup. Furthermore the green light shows that the communication between flow meter and system is intact.

Installation setups

1-meter setup

The simplest way of measuring fuel consumption is by installing a single flow meter, which measures the fuel transferred from the fuel tank to the settling tank. The level of fuel in the settling tank is typically maintained by level sensors, and therefore the flow to the settling tank is equal to what is consumed.

3-meter setup

If more detailed monitoring is desired, then a 3-meter setup can be introduced. With the 3-meter system, the total fuel consumption is monitored by flow from fuel tank to settling tank. A set of flow meters, installed on the common auxiliary fuel supply line and return line, will provide the total consumption measurement of the auxiliary engines. By subtraction, the main engine fuel consumption can be calculated. By splitting the main engine and the auxiliary engines, the crew on board as well as on shore has a much more detailed overview of how the consumers perform.

Full consumer insight

To gain full understanding of the fuel consumption, you measure on each consumer inlet and outlet. This will provide a complete insight into each consumer’s fuel consumption, and any deviations from performance expectations or norms, can easily be pinpointed. This can potentially aid in preventative maintenance planning and better utilisation of auxiliary engines.

Insatech Marine Fuel Consumption System Full Measurement Setup 16 9

Your own setup

Insatech Marine is not restricted regarding installations. Therefore if you have your own specific setup that you would prefer, we can accommodate a corresponding setup or install the system on existing flow meters. In such cases we will typically include an engine pre-inspection to ensure technical feasibility of the setup.

Installation

Insatech Marine provides you with turnkey solutions
The system installation does not generate unnecessary costs, it will not alter your schedule or put your vessel out of service. Our experienced technicians install and commission the system while your vessel is in service, whether at sea, in port or dry dock. We are ready to move out at your preferred destination and time.

Do It Yourself - or let us install

The system is programmed, calibrated and has been initially setup by our technicians to minimize installation time onboard. The crew on board will in some cases be able to install the equipment under the guidance of Insatech Marine’s technicians, to ensure correct placement and electrical installation. This minimizes cost and required man-hours, while ensuring maximum benefit of the system during use. However, we are also able to provide installation with commissioning, tests and training of the crew. We can complete the installation at sea, in port or dry dock at your preference.

Turnkey solutions and installations; at sea, in port or dry dock at your preference.

Turnkey solutions and installation

Service, Maintenance & Support

If you require a service agreement as part of the system our skilled technicians are ready to service your vessel at all times. While the system requires minimal maintenance an occasional calibration of equipment is recommended.

Service and support is readily accessible

To constantly get highly accurate measurements, your marine equipment must function optimally. This means it must be calibrated according to the purpose, and therefore we provide service options, should the need arise. This is why we have our own technicians ready for service on board your vessel at all times, whether it is a planned service visit or a pressing and acute matter that needs immediate attention.

Minimal Maintenance

As the equipment used for the Bunker Management System is mostly constituted by components without moving parts, the need for active maintenance is minimal. Nonetheless there might be equipment in need of calibration or service from time to time, and depending on the specific setup, a service and maintenance plan will be issued with each individual Bunker Management System.

Contact

System variations matching your requirements

Insatech Marine offers a broad variety of system setups all depending on which requirements you need. If you any questions you are always welcome to contact our expert(s) for more information.

Get in Touch with Our Experts

Henrik Nielsen

Sales Manager

Tel: +45 2761 4538

Email: Henrik.Nielsen@insatech.com

Write to Henrik

FAQ: System Benefits & Business Value

What is the main benefit of measuring fuel consumption accurately?

It provides key insights to adjust sailing patterns for optimal fuel efficiency and validates the savings from improvements like hull cleaning, supporting data-driven decisions

How does the system help reduce operational costs (OPEX)?

Fuel is 50% - 70% of OPEX. Accurate measurement is critical for securing profit by optimizing operations and pinpointing consumption fluctuations to achieve significant cost reduction.

Why does measurement accuracy matter for savings?

A 1% error can lead to a loss of 200 tons of fuel annually (~USD 100,000). High-accuracy Coriolis meters ensure you capture every potential saving.

How does the system help with regulatory compliance?

It automatically documents your vessel's emissions (fuel use), providing constant certainty for IMO CII rating improvement and maintenance of your SEEMP documentation.

Technology & Functionality

What type of flow meters are used and what is their accuracy?

We use Coriolis Mass Flow Meters with an accuracy better than 0.2% of nominal flow. They measure directly in mass, avoiding temperature errors common in volumetric meters.

How is fuel efficiency measured in real-time?

The system uses differential measurement (before and after engine) and correlates consumption with GPS and speed log data to calculate precise fuel efficiency (e.g., g/ton-mile).

Can the Fuel Consumption System be upgraded?

Yes. The Fuel Consumption System is the core foundation and can be easily upgraded to the more comprehensive Performance Monitoring System for deeper vessel analytics.

Data Access & Automation

Where can the operator panel be installed?

The panel can be flexibly installed in the Engine Room, Engine Control Room, or on the Bridge to ensure convenient access and faster operational response by the crew.

Is the system fully automated?

Yes, it is fully automated. Once installed, it requires no manual input or activation under normal conditions, allowing the crew to focus entirely on ship performance.

What is DataLink and how does it minimize bandwidth usage?

DataLink automatically transfers new, logged data to headquarters. It minimizes transfer size by only sending new information, working effectively even on low-bandwidth satellite connections.

Installation & Service

Does Insatech provide turnkey solutions for installation?

Yes. Our experienced technicians provide turnkey solutions and can install/commission the system while your vessel is in service (at sea, in port, or dry dock).

Can the vessel crew install the equipment?

Yes. To minimize costs, the crew can install the pre-programmed and calibrated equipment under the direct guidance of Insatech Marine's experienced technicians.

What kind of service and maintenance is required?

Maintenance is minimal due to few moving parts. However, occasional calibration is recommended. Our technicians are available 24/7 for planned or acute service needs.

Do you need fast, technical assistance?

Our service technicians can assist you via online support, phone or on board service, maintenance and repair

Read about our service team

Marine Fuel Flow Meter, Consumption Systems & Measurements