Presuming that one is following the RAW, the manpower requirement and the cost is going to be the two things that will keep the size of tankers down.
Aye. Life support and crew salaries (and the tonnage for extra staterooms requiring more hull and drive displacement) are factors that can quickly eat into profit margins (how you measure "winning") in mercantile(ish) economic models ... particularly for internal fuel capacity oriented designs.
After demonstrating a Cr 7600 cost per 1000 tons of external fuel delivered business model (
that works!) ... or basically a cost of Cr 7.6 per ton of fuel
delivered, per delivery ... it starts getting hard to see how an internal fuel tanker business model would be able to compete with that kind of performance (and strictly speaking, there's room to reduce that cost even further by omitting the Gunner!
). Without a Gunner aboard, those overhead costs (life support plus salary plus berthing fees) nosedive down to being only Cr 5100 per 1000 tons of external fuel delivered ... or basically a cost of Cr 5.1 per ton of fuel delivered, per delivery. That's basically life support for 1 stateroom (Cr 2000 per 2 weeks), salary for 1 pilot (Cr 3000 per 2 weeks) and berthing fees (Cr 100 once each round trip).
I have a REALLY HARD TIME envisioning how a larger bulk internal fuel freighter is going to be able to beat those kinds of overhead cost numbers ... even when taking the "make it up in volume" approach using gigantic multi-kiloton sized supertankers (a massive investment in capital to buy, own and operate!) in the 10-50k ton range, even as non-starships. It probably CAN be done ... but exactly HOW is not immediately apparent to me ... although I'm sure the LBB5 crew requirements of 1 engineer per 100 tons of drives would help (10k non-starship with maneuver-1 (2%), power plant-1 (3% at TL=9-12) requires 500 tons of drives, meaning 1 chief engineer plus 4 more engineering staff) ... but then there's all the extra crew in the command department to think about, so it might not "balance out" until higher tonnages than 10k.
Like I said ... it's a challenge to come up with something better at 10k+ supertanker sizes than the more flexible "just use 10+ copies of those instead" where you aren't putting all your eggs in one basket (so to speak) and have a lot more operational flexibility when it comes to scaling up or down, not to mention mass production scale efficiencies at the shipyard(s) manufacturing the design(s) since it's cheaper to make multiple copies of a small ship than it is to order a single copy an incredibly huge ship. A 10k hull size in configuration: 4 costs MCr 600 before putting any drives into it ... and maneuver-1 would cost MCr 300 for 200 tons and power plant-1 would cost MCr 900 for 300 tons ... so the 10k hull already costs
MCr 1800 in hull and drives before putting any crew spaces (bridge, computer, staterooms, etc.) into it.
Meanwhile ... the 5G TL=11 Spinward X-Courier would cost only MCr 1215.184 to buy 10 copies in mass production (plus an extra MCr 10.1 for ten 1000 ton L-Hyd drop tanks) ... while the 6G TL=13 Spinward Flex Courier would cost only MCr 1098.752 to buy 10 copies in mass production (plus an extra MCr 10.1 for ten 1000 ton L-Hyd drop tanks).
MCr 1800 for an incomplete 10k hull ... versus MCr 1225.284 (5G) or MCr 1108.852 (6G) for 10 starships that are completely built with each capable of hauling 1000 tons of fuel (10k tons total)?
NO CONTEST.
Even if you CAN get the life support/crew salary/berthing fees overhead costs fraction below that of the 194 ton "tug and barge" model, you still aren't going to be able to scale up large enough to break even when including the costs of annual overhaul maintenance (or you have to grow the internal tankage non-starship so large that it isn't even a "fair fight" anymore at 100k ton single non-starship vs 194 tons 100 starships kind of economies of scale). Now a megacorporation might be able to go so far as to reach for that kind of fuel fraction in a tanker design investment ... but "low end" operators (below megacorporation merchant lines, starport authorities serving world population codes of 8-, etc.) aren't going to be able to INVEST at the amounts of capital necessary to support such supertankers.
So ... once again ... Advantage: Spinward X-Courier and Spinward Flex Courier when it comes to the lower end market share operators.
As for the reason to have jump capability that I can see is that in time of war you can remove the tankers and purification infrastructure. If the majority of the storage is in orbit you vent or destroy the fuel there before the enemy can secure it.
Agreed.
Even if the jump capability is used only "once a year" to depart the system for maintenance (which might not be available locally) or even "never" (if maintenance IS available locally) ... being able to "retreat" out of system in the even of hostilities or even a demand for disaster relief operations in neighboring systems is still a valuable capacity to have built in, rather than being so hyper-specialized that if an invasion occurs you're stuck (and captured and put to work by and for the enemy) or if your capabilities would help out a neighboring system in need (disaster) your investments lack the means to "drop everything" and go assist them in any capacity whatsoever.
That flexibility is ... superfluous ... until it's not.
You are likely right about a smaller tug like vessel with high capacity maneuver drive to tow a larger amount of fuel to handle the manpower and cost issues.
Again ... until I started "playing with" the notion, I had a vague feeling it might be the case ... but only after actually doing some preliminary analysis (see above) do I start to see just how
crushingly obvious the economic advantages of the different business models could be.
Could a variation of the Spinward X-Courier and Spinward Flex Courier be designed that is better optimized for shuttling 1000 ton L-Hyd drop tanks (that get retained all the time in regular service) around a star system?
Sure.
It would even be smaller than 194 tons.
134 tons * 0.17 = 22.78 tons
1000 tons + 134 tons = 1134 tons * 0.02 = 22.68 tons
So 134 tons is the minimum size of a 6G maneuver tug that can still manage to generate 1G with a 1000 ton external cargo load.
134 tons of non-starship would make the total displacement of drives smaller (22.78 tons maneuver, 24.12 tons power plant) and cheaper (MCr 11.39 maneuver, MCr 72.36 power plant) ... but at a cost of internal cargo capacity if keeping the jump drive, or expanding internal cargo capacity if building a non-starship (some of which could be devoted to installing a larger fuel purification plant for gas giant to moon shuttle operations). However, such a specialized design would necessarily lose a lot of flexibility, particularly in a non-starship configuration ... so as is always the case in engineering (and biology) ... how much specialization are you willing to tolerate in your operations, understanding that increased specialization carries its own set of external risks (when your operations become too inflexible to adapt to changing market conditions, such as war and disaster response)?
Like I said ... fun to think about ...