Cylinder Condition. What will the future bring. 07 November 2018

Transcription

1 Cylinder Condition What will the future bring 07 November

2 What is ahead Different choice, different solutions. Exhaust gas Cleaning (EGC) SOx scrubber? Fuel: 0.1 to 4+% Cyl oil : BN25 & BN140 Cyl condition focus: Cold corrosion Ring wear Liner wear 2020 Fuel? Fuel: 0.1 to 0.5% Cyl oil : BN40 Cyl condition focus: Detergency Minimise liner polish Liner scuffing Duel fuel? ME-GI or ME-LGI Operate the engine on LNG, ethane, methanol or LPG 07 November

3 The future Marine emission regulation We are here Fuel Sulphur Content (Equivalent) [%] 4,5 4 3,5 3 2,5 2 All vessels (old and new) General Scrubbers 1,5 1 0,5 in ECAs 0 NO x [g/kwh] 17.0 Tier I TierII Tier III Only newbuildings US-ECA in ECAs N-EU-ECA November

4 Methanol Biofuel LPG Influencing Factors on Fuel Choice CAPEX and OPEX Fuel price Legislation Fuel choice Distillates Heavy fuel ULSFO LNG Ethane Sustainability of fuels Flexibility (dual fuel) Logistics 07 November

5 Bunker Fuel Price $/MT Bunker Fuel Price $/MT MGO (Rotterdam) Guestimate HFO (Rotterdam) 0.5%S fuel 200 DIFF: MGO - HFO 0 May Jan Sept May Jan Sept May Jan Sept May Jan Sept May Jan Sept May Jan Sept May Jan Sept May Jan Sept May Jan Sept May Jan Sept May Jan Sept May Jan Sept May Jan Sept May Jan Source: Bunkerindex November

6 Bunker Fuel Price $/MT Bunker Fuel Price $/MT MGO (Rotterdam) Guestimate HFO (Rotterdam) 0.5%S fuel 200 DIFF: MGO - HFO 0 May Jan Sept May Jan Sept May Jan Sept May Jan Sept May Jan Sept May Jan Sept May Jan Sept May Jan Sept May Jan Sept May Jan Sept May Jan Sept May Jan Sept May Jan Sept May Jan Source: Bunkerindex November

7 Viscosity distribution of RMG380 with S% 1.1 Data from Lloyds Register FOBAS Viscosity, cst at 50 C : 72% of the samples : 16% of the samples 180 or lower: 1.2% of the samples Over specified limit : 9% of the samples : 1.1% of the samples Evaluation and interpretation of the data are made by MAN ES 07 November

8 Expected viscosity distribution of future 0.50% S fuels Expected future 0.50% S fuels Data from 2017 (FOBAS) 07 November

9 Density distribution of RMG380 with S% 1.1 Density kg/m % of the samples 975 or lower 12% of the samples Over specified limit % of the samples or higher 0.01% of the samples Evaluation and interpretation of the data are made by MAN ES. 07 November

10 Expected density distribution of future 0.50% S fuels Expected future 0.50% S fuels Data from 2017 (FOBAS) 07 November

11 Fuel type characteristics 15 C kg/m3 Highly parafinic + high Pour point HFO aromatic type Don t mix Distillate (DMA) + low Pour point Kin. 50 C, cst 07 November

12 Cat fines - paper Impact on engine wear and how to reduce the wear Link to paper: 07 November

13 What is ahead Different choice, different solutions. SOx scrubber? Fuel: 0.1 to 4+% Cyl oil : BN25 & BN140 Cyl. conditon focus: Cold corrosion! Ring wear Liner wear 2020 Fuel? Fuel: 0.1 to 0.5% Cyl oil : BN40 Cyl. condition focus: Detergency Minimise liner polish Liner scuffing SameAs To Day 07 November

14 What fuel will be used in 2020 and beyond? High sulphur fuel Compliant fuel MC/ME/-C engine 0.5-5%S fuels: HFO/MDO + Scrubber MC/ME/-C engine Single Fuel: 0.1%S fuel, 0.5%S fuel ME-GI / ME-LGI engine Dual Fuel: LNG, Ethane, LPG, MeOH 07 November

15 Scrubbers High sulphur fuel MAN Energy Solutions is not a SOX scrubber maker. SOX scrubber maker and the shipowner must handle the SOX scrubber layout/egc system, installation arrangement, vessel installation interfaces, and SOX emission compliance plan. MC/ME/-C engine 0.5-5%S fuels: HFO/MDO + Scrubber MAN PrimeServ offers a SOX scrubber retrofit package with recommendations on the turbocharger re-matching parts as well as related re-certification work for the engine modifications carried out and approval with relevant classification societies. 07 November

16 Cold Corrosion Quick intro Cold Corrosion occur when the water vapour in the fumes condensate on the liner wall and form sulphuric acid High Wear from CC occur when the high BN additives in the cylinder oil cannot stop the corrosion of the liner wall The oxidised metal is scraped of by the piston rings. In case there is cat.- fines in the fuel this may accelerate the wear. 07 November

17 Cold Corrosion The solutions LDCL System RDL Liners Cylinder Oil 07 November

18 Cold Corrosion Cylinder Liner Cooling Traditional Traditional Liner Cooling. Same water amount for liner and cover Full flow in the cooling pipes 07 November

19 Cold Corrosion Cylinder Liner Cooling LDCL LDCL Liner Cooling. Separate water amount for liner and cover Temperature of the liner cooling water can be increased during part load 07 November

20 Cold Corrosion Cylinder Liner Cooling Rating Dependent (RDL) RDL Cooling. Separate number of cooling bores for High Medium and low MEP Different angel of machining for High, Medium and Low MEP CANNOT BE COMBINED WITH JBB LOW MEP HIGH MEP 16 Pipes 22 Pipes 1780 MCR MCR I I 1210 I I November

21 Cold Corrosion RD Liners A new Rating dependant liner is designed so as the temperature is the same as at high rating. Focus is in the upper part of the liner (first 300mm). L1Liner RDL Liner 07 November

22 Cylinder oil controlling cold corrosion November

23 Suppliers Choose the right cylinder oil Chevron 140 BN Cylinder Oils Taro Sp. HTULTRA SK Lubricants SK Supermar Cyl 140 Shell Shell Alexia 140 Exxon Mobile MobilGuard 5145 (145 BN) TOTAL Talusia HR 140 BP / Castrol Cyltech 140 Gulf Oil Marine GulfSea Cylcare 50140X 140 Sinopec Sinopec Marine Please see SL /JUSV 07 November

24 Suppliers Choose the right cylinder oil Please see SL /JUSV 07 November

25 Cylinder oil controlling cold corrosion 07 November

26 Cylinder oil controlling cold corrosion Iron (Fe) Total [mg/kg] Bore Bore Bore Danger Do not operate in this area Alert Area, adjustment may beneeded Safe Area Risk of linerpolish % of nominalbn 0 25BN Drain Oil November BN 70BN 100BN 140BN

27 Drain Oil Evaluation Laboratory 07 November

28 Service Experience Cylinder Condition 12S90ME-C9.2TII BN 100 Cyl. Oil Sweep showed a need for a FRF of 0.28 [g/kwh x %S] BN average FE average November

29 Cylinder oil How Drain Oil data is used Note.: Feed Rate Factor (FRF) Fe & BN values are different for all engines, below values is a Theoretic example and not general for all engines. Ship Delivery 27/03/2017 SWEEP TEST RESULT FRF ADJUSTED START 5 DaySWEEP 03/08/2017 Drain Oil RESULT show to high Fe 01/02/ /03/ / 04/ /05/ /06 / /07/ /08/ /09/ /10/ /11/ /12/ /01/ /02/ /01 /2017 FRF = 0.40 FRF = 0.33 FRF = 0.36 FRF = /03/ November

30 Drain Oil Evaluation Onboard TOTAL Fe (MDT RECORMENDATION) Magnetic Fe + = NON Magnetic Fe 07 November

31 Drain Oil Evaluation Onboard Kittywake Parker FWM Exxon Mobile MSA TOTAL Fe Magnetic Fe Shell Analex Kittywake Parker Liner Scan MFT, SEAMATE CMT Total FeTest Kittywake Parker CC test kit NON Magnetic Fe Chevron DotFast 07 November

32 Onboard Vs. Onshore On board testing to be used as Red light / Green light. Samples can be taken more frequent every week, and when switching fuel. Lab analysis to be used for feed rate adjustment Take on board measurement every 2 weeks, and send samples ashore every month. 07 November

33 Cylinder oil controlling cold corrosion Cylinder oil dosage must be controlled according to the fuel Sulphur to control the cold corrosion Fuel Sulphur g/kwh November

34 Cylinder oil controlling cold corrosion Example: Feed Rate Factor (ACC) and fuel Sulphur of 2.7 % Cylinder oil dosage must be 1.03 g/kwh Fuel Sulphur g/kwh November

35 Cylinder oil controlling cold corrosion Example: Feed Rate Factor (ACC) and fuel Sulphur of 2.1 % Cylinder oil dosage must be 0.80 g/kwh Fuel Sulphur g/kwh November

36 What is ahead Different choice, different solutions. Summery. o When ordering engines for Scrubber application, the engine must be fitted with anti Cold Corrosion measures (RD Liners + LDCL system. o Cylinder oil to be used: High BN 100BN + o Think about cylinder oil mixing (ACOM) for greater variation of the Cylinder oil BN o Used Cylinder oil Drain oil data is key of keeping the cold corrosion under control. 07 November

37 What is ahead Different choice, different solutions. SOx scrubber? Fuel: 0.1 to 4+% Cyl oil : BN25 & BN140 Cyl con fokus: Cold corrosion! Ring wear Liner wear 2020 Fuel? Fuel: 0.1 to 0.5% Cyl oil : BN40 Cyl con fokus: Detergency Minimise liner polish Liner scuffing 07 November

38 Expected density distribution of future 0.50% S fuels 2020 Challenge: When the density changes from e.g. high to lower, the gravity disc must be changed in older separators - when switching between batches. If gravity disc doesn t fit with the fuel in use, the fuel will either not be cleaned from water, or the fuel will be let to the drain? Solution: Be aware of the density of the fuels: in-use and next batch If necessary change the gravity disc 07 November

39 Expected viscosity distribution of future 0.50% S fuels 2020 Challenge: When the viscosity distribution is more evenly divided within the same ISO 8217 grade (e.g. RMG380), two different fuel batches from the same grade may have different viscosity. Fuels with different viscosity must be heated to different temperatures to reach the same viscosity. Solution: The fuel system will experience temperature change more often - when switching between batches. If temperature and viscosity is not controlled correct: A lower viscosity fuel may be heated too high, making the viscosity too low, which may lead to seizures in the engine fuel pump. A higher viscosity fuel may not be heated sufficient, making the viscosity too high, which may lead to insufficient atomisation of the fuel and possible bad combustion. Make sure the viscorater is working - and set to max. 2 cst/min. 07 November

40 Testing new 0.50%S fuel for 2020 Testing new types of fuel, we recommend to do lab analysis as follows: 1. ISO : All parameters 2. Cold flow properties: important for both residual and distillate grades: a. Pour point (ISO 3016) b. Cloud point (ISO 3015) c. Cold filter plugging point (45 µm filter, 60 sec., ASTM D6371 or see ISO ) 3. Stability within the fuel and compatibility to other fuels should also be investigated. E.g. TSE/TSP/TSA (ISO /2) 4. ECN analysis (IP 541/06) This analysis will give indication on combustion properties 5. Boiling curve (ASTM D1160) This analysis will give indication on composition of the fuel 6. Elements: H, C, N, S, O in m/m%. E.g. ASTM D5291, ASTM D5762, ASTM D November

41 Service testing new 0.50%S fuel for 2020 Service testing new types of fuel, we recommend to do as follows: 1. Take samples of fuel on board and send for analysis a. 0.50% S fuel b. High-S fuel c. <0.10%S fuel: Distillate or other fuel type 2. Do spot testing on board (ASTM D4740) a. 0.50%S fuel alone b. High-S fuel alone c. 0.50%S fuel vs high-s fuel: (and and 20-80) d. 0.50%S fuel vs distillate: (and and 20-80) 3. Cylinder lube drain oil from operation on: a. 0.50%S fuel b. High-S fuel 4. Scavenge port inspection a. Before start of test b. After test Don t mix Viscosity Density Empty tanks 5. Inspect Observe - take note on the fuel system during the 0.50%S testing a. Separators b. Filters c. Drains d. Tanks e. Fuel pumps f. More? 6. Make performance evaluation. Operation on: a. High-S fuel b. <0.10%S fuel c. 0.50% S fuel 07 November

42 We can learn from the 0.10% SECA ULSFO < 0.10% Sulphur There are a range of different types fuels. These are not distillate types, rather new blends or types. Service letter SL General characteristics are: Higher viscosity than distillate Some contain cat fines (Al+Si) Some have high pour points Compatibility with other fuels may also be an issue. 07 November

43 2020 -> Solutions, Fuel tanks Pre 2020: Few big fuel tanks Post 2020: Multiple smaller fuel tanks 07 November

44 Summary Future fuels 1. Max. 0.1% S fuels a. Distillate b. ULSFO-RM -> 0.50% S fuel? 2. Max. 0.5% S fuels a. Very diverse properties b. Challenges similar to ULSFO-RM -> Try to use an ULSFO-RM to gain experience 3. High-S fuels a. Up to 4.5-5% S 4. Alternative fuels a. LNG b. Methanol, LPG, Ethane, biofuel, 5. Cat fines (Al+Si) are and will be in the fuels and they have to be removed. Service Letters: SL SL SL SL SL SL November

45 Cylinder Oil 07 November

46 Cylinder Condition Actual Ship Running Distillate Open Examples of Liner surface Cat. Fines Party closed Closed with seizers Polished surface lead to smeared Surface 07 November

47 Cylinder Condition Piston ring for ULS Service Letter SL Introducing Full cermet coated ring packs for ULS operations (ME-C-GI). Note: Engine in service: Evaluate cylinder liner surface before mounting Cermet Coated Ring. It can be refreshed by Wave-cut grinding 07 November Note: below 50 bore: Cermet coated rings will be of CPR type, not POP

48 Cylinder Condition Piston ring for ULS Just issued SL /JAP NEW Service Letter conserning 0.5% fuel operation. Apply Cermet coated rings Note: Engine in service: Evaluate cylinder liner surface before mounting Cermet Coated Ring. It can be refreshed by Wave-cut grinding 07 November Note: below 50 bore: Cermet coated rings will be of CPR type, not POP

49 Cylinder Condition Piston ring for ULS 07 November

50 Cylinder oil controlling cold corrosion 07 November

51 Cylinder oil controlling cold corrosion When Operating on Low Sulphur fuel, cold corrosion will not be a major issue (- Sulphur) 07 November

52 Cylinder oil controlling cold corrosion Cold Corrosion is dismissed when using 0.5% Sulphur The new challenge is to keep the pistons clean (Detergency) 07 November

53 Cylinder oil controlling cold corrosion FRF 1.00 BN40 FRF 0.40 BN100 Cylinder oil Feed Rate Factor (ACC) are to be adjusted according to the BN in the oil FRF and BN Same engine two different oils 07 November

54 Cylinder oil controlling cold corrosion Cylinder oil Feed Rate Factor (ACC) are to be adjusted according to the BN in the oil FRF and BN Same engine two different oils 07 November

55 High BN Vs Low BN low BN cyl oil & Gas / HFO operation After 10 days on high BN cyl oil and LNG / HFO Opertion P2 Port side Unit #3 P2 Port side Unit #3 P1 Stbd side Unit #2 P1 Stdb side Unit #2 07 November

56 Cylinder oil Cylinder oil system Secondary cylinder oil 100BN? Primary cylinder oil 40BN Typical setup of storage and service tanks on-board a ship 07 November

57 What is ahead Different choice, different solutions. Summery. o When ordering engines for Scrubber application, the engine must be fitted with anti Cold Corrosion measures (RD Liners + LDCL system. o Cylinder oil to be used: High BN 100BN + o Think about cylinder oil mixing (ACOM) for greater variation of the Cylinder oil BN o Used Cylinder oil Drain oil data is key of keeping the cold corrosion under control. o Operating on very low sulphur fuel 0.5% will increase the risk of liner polish, and may lead to liner scuffing. o Cermet coated piston rings are introduced. o Cylinder lubrication, detergency. 07 November

58 Disclaimer All data provided in this document is non-binding. This data serves informational purposes only and is especially not guaranteed in anyway. Depending on the subsequent specific individual projects, the relevant data may be subject to changes and will be assessed and determined individually for each project. This will depend on the particularcharacteristics of each individual project, especially specific site and operational conditions. 07 November

59 Thank you very much! 07 November