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Combined diesel and gas
Combined diesel and gas
Combined diesel and gas
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Principle of a CODAG system, with two speed diesel gearboxes

Combined diesel and gas (CODAG) is a type of propulsion system for ships that need a maximum speed that is considerably faster than their cruise speed, particularly warships like modern frigates or corvettes.

Pioneered by Germany with the Köln-class frigate, a CODAG system consists of diesel engines for cruising and gas turbines that can be switched on for high-speed transits. In most cases the difference of power output from diesel engines alone to diesel and turbine power combined is too large for controllable-pitch propellers to limit the rotations so that the diesels cannot continue to operate without changing the gear ratios of their transmissions. Because of that, special multi-speed gearboxes are needed. This contrasts to combined diesel or gas (CODOG) systems, which couple the diesels with a simple, fixed ratio gearbox to the shaft, but disengage the diesel engines when the turbine is powered up.

For an example the new CODAG-propelled Fridtjof Nansen-class frigates of the Royal Norwegian Navy, the gear ratio for the diesel engine is changed from about 1:7.7 (engine:propeller) for diesel-only to 1:5.3 when in diesel-and-turbine mode. Some ships even have three different gear ratios for the diesel engines — one each for single-diesel and double-diesel cruises, and the third when the gas turbine is engaged.

Such a propulsion system has a smaller footprint than a diesel-only power plant with the same maximal power output, since smaller engines can be used and the gas turbine and gearbox don't need that much additional space. Still, it retains the high fuel efficiency of diesel engines when cruising, allowing greater range and lower fuel costs than with gas turbines alone. On the other hand, a more complex, heavy and troublesome gearing is needed.

Typical cruising speed of CODAG warships on diesel-power is 20 kn (37 km/h; 23 mph) and typical maximal speed with switched on turbine is 30 kn (56 km/h; 35 mph).

Turbines and diesels on separate shafts

[edit]
Combined marine propulsion

Combined diesel or gas (CODOG)
Combined diesel and gas (CODAG)
Combined diesel-electric and diesel (CODLAD)
Combined diesel–electric and gas (CODLAG)
Combined diesel and diesel (CODAD)
Combined steam and gas (COSAG)
Combined gas or gas (COGOG)
Combined gas and gas (COGAG)
Combined gas and steam (COGAS)
Combined nuclear and steam propulsion (CONAS)
Integrated electric propulsion (IEP or IFEP)

Sometimes the engine arrangement of diesel engine and gas turbine with each system using its own shafts and propellers is also called CODAG. Such installations avoid the use of a complicated switching gearbox, but have some disadvantages compared to real CODAG systems:

  • Since more propellers have to be used, they have to be smaller and thus less efficient.
  • The propellers of the idling systems cause drag.

CODAG WARP

[edit]

CODAG Water jet And Refined Propeller (WARP), a system developed by Blohm+Voss as option for their MEKO line of ships, also falls in this category, but avoids the above-mentioned problems. CODAG WARP uses two diesel engines to drive two propellers in a combined diesel and diesel (CODAD) arrangement, i.e., both shafts can also be powered by any single engine, and a centerline water jet powered by a gas turbine.[1] The idling water jet does not cause drag, and since its nozzle can be placed further aft and higher it does not affect the size of the propellers.

CODAG-electric

[edit]

Another way to combine the two types of engines is to connect them to generators and drive the propellers electrically as in a diesel-electric. See Combined diesel–electric and gas (CODLAG) and Integrated Electric Propulsion (IEP). This also permits propeller pods, with the propulsion motors being located inside the pods.

Land vehicles

[edit]

The Swedish Stridsvagn 103 utilizes a diesel engine for slow cruising and aiming, and a gas turbine for additional power..[2]

See also

[edit]

References

[edit]
[edit]
Revisions and contributorsEdit on WikipediaRead on Wikipedia

Combined diesel and gas

View on Grokipedia
from Grokipedia
Combined diesel and gas (CODAG) is a system that combines diesel engines for efficient low- to medium-speed cruising with gas turbines for high-speed boost, enabling ships to achieve maximum speeds significantly higher than their economical cruise speeds while optimizing fuel consumption across operational profiles. In a typical CODAG configuration, diesel engines drive the shaft directly or through a gearbox for routine operations, where their high and reliability excel at partial loads. For demanding high-speed scenarios, such as combat maneuvers or , gas turbines are clutched in to provide additional power, often delivering up to 40,000 kW per unit and leveraging their superior . The system employs a complex gearbox to synchronize and engage the prime movers selectively or in tandem, ensuring smooth power delivery to fixed-pitch or controllable-pitch s, waterjets, or other propulsors. Key advantages of CODAG include enhanced fuel economy during extended low-speed voyages, rapid acceleration to sprint speeds governed by the cube law of ship resistance, and reduced overall machinery weight and volume, which free up space for weapons, sensors, or in naval designs. Gas turbines contribute lower and at high speeds, improving stealth, while the setup supports high through redundant power sources and shock-resistant components. Drawbacks encompass higher upfront costs, increased from dual engine types, and potential inefficiencies if gas turbines run infrequently due to their higher specific consumption. CODAG has been widely adopted in modern naval frigates and corvettes for its balance of endurance and sprint capability, with notable examples including the German Sachsen-class (F124) frigates, equipped with GE LM2500 gas turbines for 29-knot speeds; the Norwegian Fridtjof Nansen-class, achieving 27 knots; the South African Valour-class (MEKO A-200), at 28 knots; and the Turkish MILGEM corvettes. It also powers U.S. National Security Cutters for multi-mission patrol duties, and select commercial applications like fast ferries where speed versatility is critical. Variants such as CODLAG (with electric drive integration) extend these benefits to hybrid-electric architectures for even quieter operations.

Fundamentals

Definition and principles of operation

Combined diesel and gas (CODAG) is a hybrid marine propulsion system that integrates diesel engines for efficient low- to medium-speed operations with gas turbines for high-speed boosts, enabling vessels to achieve maximum speeds typically 1.5 to 2 times the cruising speed. In this configuration, diesel engines handle cruising duties at speeds around 20 knots, while gas turbines engage to provide additional power for sprints up to 30 knots or more, optimizing fuel consumption across varying operational demands. The principles of operation rely on selective engagement of power sources to match mission profiles without compromising efficiency. Diesel engines connect directly to shafts via clutches and reduction gears for economical during transit or , where they excel at partial loads due to their high (specific fuel consumption of 0.17–0.20 kg/kWh). Gas turbines, which offer higher power density but lower efficiency at low speeds, are clutched in separately or in parallel with the diesels for high-speed maneuvers, combining power through a central gearbox to add without overloading the diesel components. This setup allows seamless transitions between modes—diesel-only for , gas-only for rapid if needed, and combined for peak performance—ensuring the system maintains uniform vessel response. Key components include mechanisms, such as hydraulic or clutches, that engage or disengage the prime movers to prevent drag from inactive engines, and reduction gears that synchronize rotational speeds between the higher-revving gas turbines and lower-speed diesels with the propeller shaft. Power matching typically allocates 50-70% of total capacity to diesels (e.g., up to 20,000 kW per ) for baseline needs, with gas turbines contributing 30-50% (e.g., 40,000 kW) for boosts, reflecting diesel dominance in curves at partial loads where gas turbines underperform. Fuel is maximized by diesel operation below threshold speeds, with gas engagement limited to short bursts to minimize consumption penalties. In a basic schematic, parallel power paths from diesels and gas turbines merge at a combining gearbox before driving the shaft, represented by the total power output equation: Ptotal=Pdiesel+PgasP_{\text{total}} = P_{\text{diesel}} + P_{\text{gas}} where PgasP_{\text{gas}} is zero below the engagement threshold speed and additive thereafter, ensuring proportional load sharing (e.g., 60% diesel, 40% gas at full load). This mechanical integration via clutches and gears distinguishes CODAG from purely electric hybrids, focusing on direct shaft drive for responsive naval applications.

Historical development

The development of combined diesel and gas (CODAG) propulsion systems emerged in the mid-20th century as naval engineers addressed the limitations of standalone diesel engines, which provided excellent fuel efficiency for cruising but insufficient power for high-speed operations in warships. Influenced by earlier combined steam and gas (COSAG) systems pioneered by the British Royal Navy in the 1950s, such as those tested on destroyers like the County-class (e.g., HMS Devonshire), CODAG concepts shifted toward integrating reliable, low-speed diesels with high-power gas turbines to optimize both economy and sprint capability. Initial proposals in the 1950s responded to the need for versatile escorts capable of sustained patrols and rapid response, drawing on advancements in gas turbine technology from firms like Brown, Boveri & Cie (BBC), which developed compact units suitable for marine applications. Key milestones in the 1960s marked the transition from concept to operational reality, with and other European firms leading the engineering efforts. The German Navy's Köln-class frigates, designed starting in 1955 and commissioned from 1962 onward, became the world's first ships equipped with CODAG propulsion, featuring four MTU diesel engines for cruising and two gas turbines for boosts up to 32 knots. This configuration demonstrated the feasibility of clutched power combination on separate shafts, setting a precedent for NATO-aligned navies seeking balanced performance without the complexity of steam plants. By the 1970s, adoption expanded amid pressures for fast, reliable escorts; for instance, the Dutch Navy explored similar hybrid systems in frigate designs, while further German developments built on Köln's foundation, influencing widespread integration for roles. Technological evolution accelerated in the with the replacement of manual mechanical clutches by automated, electronically controlled systems, enabling seamless mode switching and reducing crew demands, as seen in Danish modular designs that incorporated CODAG variants. Post-2000, integration of digital monitoring and control systems further enhanced reliability, allowing real-time diagnostics and through integrated electronic ship control platforms. Recent advancements up to 2025 have focused on lightweight composite materials for gas turbine enclosures, achieving up to 50% weight reductions compared to traditional designs and improving overall system efficiency by minimizing hull impacts. These innovations were driven by post-Cold War emphases on fuel economy, spurred by the and subsequent energy concerns, which prompted refinements in turbine efficiency for sustained operations.

Configurations

Separate shaft systems

In the standard combined diesel and gas (CODAG) configuration known as separate shaft systems, each propeller shaft operates independently, with dedicated diesel engines for efficient cruising and a gas turbine for high-speed boosts, eliminating the need for complex cross-shaft power transfer mechanisms. Typically, this setup features one or two diesel engines per shaft to provide at lower speeds, paired with a single gas turbine per shaft that engages only when additional power is required, allowing for modular operation without mechanical interdependence between shafts. This design simplifies by avoiding shared gearing across shafts, reducing potential failure points and complexity in naval applications. Operational modes in separate shaft CODAG systems prioritize efficiency and flexibility. At low to medium speeds, typically 15-20 knots, only the diesel engines drive the propellers, with clutches disengaging the gas turbines to minimize drag and preserve . For high-speed dashes exceeding 30 knots, the gas turbines can operate independently or in combination with the diesels, where clutches engage the turbines while the diesels continue contributing power through the same shaft, enabling sustained maximum speeds without overloading individual engines. This clutch-based switching ensures seamless transitions, with the gas turbines clutched out during cruising to prevent unnecessary rotational losses. Key engineering features address the significant speed differentials between power sources. Diesel engines in these systems typically operate at 1,000-1,800 RPM, requiring robust reduction gearboxes to match propeller speeds of around 200-300 RPM, while gas turbines run at higher 3,000-3,600 RPM and use separate, high-ratio reduction gears for integration. Power ratios often favor the gas turbine for bursts, such as two 2.2 MW diesels per shaft for cruising alongside an 8.8 MW gas turbine for boosts, as seen in early implementations. These gearboxes, often planetary types, incorporate locking mechanisms to isolate inactive components, ensuring reliable distribution. Performance metrics highlight the efficiency gains of separate shaft CODAG over pure gas turbine . At cruising speeds, fuel consumption is significantly lower—retaining the superior specific fuel consumption of diesels (around 190-210 g/kWh) compared to gas turbines (250-300 g/kWh)—resulting in 20-30% better economy and extended range for missions. The Köln-class frigates of the , commissioned in the , exemplify this setup with two shafts each driven by two 2.2 MW MAN diesels for 18-knot cruising and 8.8 MW Brown Boveri gas turbines for up to 32 knots, demonstrating reliable integration of mechanical components for roles.

CODAG WARP

The CODAG WARP (Combined Diesel and Gas - Water Jet and Refined Propeller) propulsion variant integrates diesel engines driving fixed-pitch propellers with a gas turbine powering an azimuthing waterjet, enabling optimized performance across speed regimes without a complex combining gearbox. Developed by (now part of thyssenkrupp Marine Systems) as an option for the modular family, this system separates duties to leverage the strengths of each component: propellers for efficient, stable low-speed operation and waterjets for high-speed thrust and agility. In operation, the diesel engines provide economical cruising at around 20 knots, offering superior and directional stability through the fixed propellers, which are optimized for sustained low-to-medium speeds. For boost modes, the gas turbine engages the waterjet to achieve sprint speeds exceeding 28 knots, while also facilitating precise maneuvering via the azimuthing , which supports up to 360-degree for enhanced low-speed control in harbors or scenarios. This separation eliminates the need for a shared gearbox, as the diesel shafts connect directly to the propellers and the gas turbine to the waterjet pump, simplifying mechanical integration and reducing potential failure points. Design advantages include minimized at high speeds, as the waterjet replaces propeller-based during sprints, avoiding tip vortex issues that degrade and increase on fixed blades. Power distribution typically allocates about 60% to the diesels for primary cruising duties and 40% to the gas turbine-waterjet combination for bursts, balancing engine wear and fuel consumption across missions. A representative example is the South African Navy's Valour-class (MEKO A-200 SAN) frigates, commissioned in the mid-2000s, which employ two MTU 16V 1163 TB93 diesel engines (each 5,920 kW) for the propellers and a GE LM2500 gas turbine (19,750 kW) for a waterjet, demonstrating the system's viability in modern corvettes and frigates. Maintenance in CODAG WARP systems focuses on the distinct propulsors, with routine adjustments to the waterjet's steering nozzles required to ensure precise vectoring and prevent efficiency losses from misalignment or debris accumulation. Unlike unified shaft systems, this setup allows independent servicing of diesel-propeller and gas-waterjet components, though periodic impeller inspections and nozzle calibrations are essential for the waterjet to maintain and azimuthing capabilities.

CODAG-electric

In CODAG-electric systems, diesel engines drive generators that supply to propulsion motors mounted on the shafts, enabling efficient low- to medium-speed operations through electric transmission. The gas turbine can either provide direct mechanical power to the shafts via a gearbox for high-speed boosts or generate additional to augment the , allowing flexible integration of power sources without complex mechanical clutches. This configuration, often implemented as an integrated electric drive (IED), supports variable shaft speeds by leveraging control, optimizing fuel use across operational modes. Power flow in CODAG-electric setups typically operates in diesel-electric mode for cruising, where diesel generators power the electric motors directly, achieving high efficiency at partial loads. For maximum power, the system combines diesel-electric output with gas turbine contribution, either mechanically or electrically, to reach sprint speeds exceeding 25 knots. Key features include advanced , such as frequency converters and inverters, that enable seamless mode switching between diesel-electric cruising and combined high-power operation without mechanical interruptions, improving maneuverability and reducing wear. A prominent naval example is the French Navy's FREMM-class frigates, introduced in the , which employ a CODAG-electric variant with four MTU 20V 4000 diesel generators (each 2.2 MW), two 2.5 MW electric motors, and a GE LM2500+G4 gas turbine (32 MW) for integrated delivering up to 27 knots. These systems offer 10-15% weight savings compared to purely mechanical CODAG arrangements by eliminating heavy reduction gears and clutches in favor of compact electric distribution.

Advantages and limitations

Key benefits

CODAG systems provide superior fuel economy compared to single-mode by leveraging diesel engines for efficient operation at partial loads, where their specific fuel consumption is typically around 191 g/kWh, significantly lower than the around 215-230 g/kWh for gas turbines at full load. This configuration allows diesels to handle cruising speeds, minimizing use during extended low-to-medium power demands, while gas turbines engage only for brief high-speed boosts, resulting in overall fuel savings of more than 10% relative to pure diesel or gas-only systems in hybrid naval applications. The systems offer enhanced speed flexibility, enabling efficient cruising on diesel power for long-range operations and rapid acceleration to sprint speeds via gas turbine augmentation, without the inefficiency of running high-fuel-consumption gas turbines continuously. This approach also contributes to reduced emissions, with hybrid control strategies in CODAG-like setups achieving notable reductions compared to pure diesel operation. Versatility is a core strength of CODAG, with modular designs scalable for vessels from 1,000 to 10,000 tons, allowing adaptation to diverse naval roles such as frigates and corvettes through tailored diesel-gas combinations that support both and auxiliary loads. The brief engagement of gas turbines further enables quieter operation, reducing acoustic signatures for stealthy missions by limiting continuous high-noise diesel or gas running. Reliability is bolstered by redundant power sources, providing between diesel and gas components, as demonstrated by in clutch installations in systems like British Type 23 frigates, Japanese Asuka-class, and Korean FFX Batch II frigates. Proven deployment in dozens of navies underscores lifecycle cost reductions through optimized engine utilization and maintenance, enhancing operational dependability in demanding environments.

Operational challenges

CODAG systems introduce significant operational complexity due to the integration of multiple power trains, including diesel engines, , , and gearboxes, which create additional failure points compared to single-engine configurations. For instance, the intricate coupling arrangements required to manage power differentials between diesel and operations have led to engineering challenges in vessels like the U.S. Navy's Littoral Combat Ships (LCS), where and seal failures have compromised reliability. This multiplicity of components elevates the risk of mechanical issues, such as wear from repeated engagements during mode transitions, demanding precise synchronization to avoid stress. Maintenance demands are heightened in CODAG setups, as gas turbines necessitate specialized overhauls that are more frequent and labor-intensive than those for diesel engines alone. While diesel engines typically achieve time-between-overhauls (TBO) of 15,000 to 50,000 hours depending on load and , marine gas turbines often require hot gas path inspections around 24,000 equivalent operating hours (EOH) and major overhauls at 48,000 to 50,000 EOH, involving module removal that cannot be performed on the vessel. Integration challenges, including vibration synchronization between disparate engine types, further complicate routine servicing, particularly with reduced crew sizes on modern naval platforms, leading to higher life-cycle costs for . Performance trade-offs manifest during transitions between diesel and gas turbine modes, where power mismatches can result in temporary efficiency losses and suboptimal shaft speeds. In CODAG configurations, diesels must operate effectively both independently and with turbines boosting , potentially causing strain if synchronization is imperfect, as seen in LCS vessels requiring larger turbines for high-speed sprints that strain overall system . These systems are also generally unsuitable for very small vessels, with practical implementations typically limited to ships exceeding 1,000 tons due to space and weight constraints for the combined machinery. Environmentally and operationally, CODAG systems face issues from higher emissions during gas turbine startups, where cold starts produce elevated and CO levels before catalysts reach operating temperature, contrasting with the steadier emissions profile of diesel-only operation. Recent developments as of 2025 include explorations of and blends in CODAG systems to mitigate emissions. In extreme conditions, such as environments, reliability can diminish due to icing on gas turbine air intakes, which disrupts and increases the risk of compressor stalls or flameouts, a concern amplified in hybrid setups lacking dedicated de-icing for turbine components.

Applications

Combined diesel and gas (CODAG) propulsion systems are primarily employed in frigates and destroyers designed for (ASW) and anti-air warfare (AAW) roles, where the need for efficient, quiet cruising on diesel engines contrasts with the requirement for high-speed dashes using gas turbines. This configuration enables vessels to maintain low acoustic signatures during extended patrols, essential for detecting submerged threats, while providing rapid acceleration to over 30 knots for evasion or pursuit. In separate shaft arrangements, such as those in the U.S. Navy's (LCS) class, diesel engines power dedicated waterjets for economical transit, while gas turbines drive separate jets for boost mode, optimizing fuel use and maneuverability in littoral environments. Notable examples include the Italian Navy's Bergamini-class (FREMM) frigates, commissioned from 2012 onward, which integrate CODLAG with two diesel generators, two electric motors, and one gas turbine for versatile ASW and AAW operations across the Mediterranean and beyond. Similarly, the Royal Netherlands Navy's De Zeven Provinciën-class frigates, entering service in the early , employ CODOG to support task forces with speeds up to 29 knots and enhanced endurance for blue-water missions. Post-2020 developments have incorporated hybrid battery systems in CODAG variants for ultra-quiet "silent mode" operations. The UK's Type 26 frigates, with construction advancing through the 2020s and first deliveries expected by 2028, represent a shift toward integrated electric CODAG (CODLAG) architectures, further reducing detectability for high-threat environments. Tactically, CODAG supports "sprint-and-drift" maneuvers in ASW, where ships accelerate on gas turbines to reposition, then revert to silent diesel or hybrid-electric drift to deploy without alerting adversaries, enhancing detection ranges and evasion capabilities. The system's modular power generation also yields surplus capacity—often exceeding 20 MW in mid-sized frigates—for energizing advanced radars, electronic warfare suites, and directed-energy weapons, ensuring sustained without compromising . CODAG and its variants power numerous naval vessels worldwide, reflecting widespread adoption across alliances like for interoperable fleet operations.

Commercial and land uses

In commercial marine applications, CODAG propulsion systems find primary use in high-speed ferries and select supply vessels, where they enable efficient operation across a range of speeds by combining diesel engines for sustained low-to-medium power with gas turbines for high-speed bursts. The Aquastrada-class passenger ferries, constructed in the mid-1990s by Rodriguez Cantieri Navali in , exemplify this approach; each vessel employed two MTU diesel engines for economical cruising at 18 knots and integrated gas turbines to achieve peak speeds of 30 knots, optimizing performance on passenger routes with variable demands. The MDV 3000 Jupiter-class ro-ro fast ferries, built by starting in 1999 for Italian operator , further demonstrate CODAG's commercial viability; these 101-meter vessels used two 22 MW GE LM2500 gas turbines alongside four 6.7 MW Pielstick diesel engines in a CODAG arrangement, delivering speeds exceeding 40 knots while accommodating 1,800 passengers and 460 vehicles on Mediterranean routes. This configuration allows diesel-only operation for fuel-efficient transit at moderate speeds, with gas turbines clutched in for sprint capability, reducing overall fuel use by up to 20% on mixed-speed itineraries compared to pure diesel setups. CODAG systems in these ferries also align with emissions regulations, such as the IMO 2020 global sulfur cap limiting fuel sulfur content to 0.50% m/m outside emission control areas, by relying on efficient diesel engines compatible with very low oil (VLSFO) for routine operations. Gas turbines in the setup can similarly utilize compliant fuels, supporting reduced emissions without extensive retrofits. On land, CODAG adaptations for commercial vehicles like high-performance trains remain experimental and uncommon, primarily explored in during the mid-20th century to enhance traction on non-electrified lines. The German Deutsche Bundesbahn's V 169 prototype , completed in May 1965 and later classified as Class 219, integrated a 1,603 kW MD 652 DB for primary hauling with a 671 kW gas turbine for boost during rapid acceleration and steep gradients, attaining a top speed of 130 km/h. An evolved design, the Class 210 locomotive delivered at the end of 1970, paired a more powerful 1,864 kW MTU 16V 652 diesel with an AVCO Lycoming gas turbine offering 742–913 kW supplemental power, similarly capped at 130 km/h for express services. Despite these innovations for improved hill-climbing and startup, the systems were discontinued by the in 1978 owing to excessive fuel consumption and elevated maintenance demands relative to pure diesel alternatives. By 2025, commercial land applications of CODAG—such as in heavy trucks or locomotives—persist only in niche prototypes, constrained by the need for dedicated fuel infrastructure, compact vehicle space limitations, and elevated implementation costs that hinder scalability beyond or specialized hybrid contexts.

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