Quantitative Regime Comparison and Engine Performance Assessment: Regime-Dependent Baselining and Comparison for In-Service Propulsion Evaluation

The in-service assessment of marine propulsion engines requires more than nominal rating comparison because operating severity is shaped by propeller demand, resistance growth, air-path response, and thermal state. This study develops a quantitative benchmarking method for the regime-dependent performance assessment of a low-speed two-stroke Wärtsilä 6RT-flex58T-D engine installed on a 31,000 DWT multi-purpose container vessel. The method integrates certified sea-trial measurements, endurance-test records, manufacturer load-diagram constraints, and a 15% service-margin projection within one reference framework. Three representative regimes are evaluated: a measured light-running baseline (SR1), a measured thermally stabilised sustained regime (SR2), and a projected heavy-running regime derived from the baseline using a 15% sea-margin assumption (R2). Comparison is performed using indicators of operating-point position, shaft torque, propeller-law consistency, selected air-path and thermal variables, load-diagram proximity, and corrected specific fuel oil consumption where available. The SR1 baseline followed the fitted propeller law with deviations not exceeding 1.18%, confirming a coherent light-running reference. In SR2, corrected SFOC decreased from 174.4 to 172.0 g/kWh, while the exhaust temperature before turbine increased from 359 °C to 435 °C, and the corresponding thermal margin decreased from 156 °C to 80 °C. Under the +15% service-margin projection, the required shaft power at the 100% trial point increased from 12,046.0 to 13,852.9 kW, exceeding the 13,560 kW installation MCR by 2.2%, with corresponding 15% increases in torque and BMEP. These results demonstrate that measured baseline operation, sustained-load severity, and projected heavy-running demand can be distinguished quantitatively within one installation-specific load-diagram-based benchmarking framework.