MONITORING SOLUTION FOR MARINE MAIN ENGINE CYLINDERS PROTECTION

Transcription

1 COLD CORROSION MONITORING SOLUTION FOR MARINE MAIN ENGINE CYLINDERS PROTECTION

2 UNIMARINE MARINE ENGINES CYLINDERS SCRAPE-DOWN OIL ANALYSIS (CSDOA) FOCUS ON PREVENTIVE MAINTENANCE UniMarine provides high performance marine lubricants and innovative marine lubrication solutions here, there and everywhere. UniMarine additionally offers LUBESAFE range of sophisticated technical services with a particular focus on marine main engine liners protection and wear monitoring. MARINE MAIN ENGINE PROTECTION Unimarine has developed a unique piston underside oil analysis program: the Cylinder Scrape-Down Oil Analysis (CSDOA), to monitor marine main engine cylinder liners COLD CORROSION issue. COLD CORROSION Lately, in order to improve fuel oil consumption and reduce emissions, new sailing and operating practices have emerged such as slow steaming or super slow steaming, especially at engine low load. There are different modes of slow steaming: reduced speed, moderate slow steaming, deep slow steaming and ultra-slow steaming. Proven benefits include higher fuel savings and significant reduction in carbon emissions (CO2, NOX and SOX.Main marine engine manufacturers (OEM) have consistently supported and endorsed ship operators running their fleet under slow steaming modes. However, most ships operating at slow steaming are equipped with engines which have not been fully designed for running at low loads or under slow steaming conditions. Marine modern engines designs which include long strokes and super long strokes features fall under that category. Hence high combustion chamber pressure and liner cooling intensity, together with the increased operating time at low load (slow steaming) generate cold corrosion on the cylinder liners which is actually a corrosive wear caused by acid condensation resulting from a drop in engine operation temperature during the slow steaming mode or when the overall length of the stroke is increased due to engine design. Cold Corrosion Solution Monitoring for Marine Main Engine Cylinders SOPHISTICATED OIL ANALYSIS PROGRAM Unimarine Cylinder Scrape-Down Oil Analysis (CSDOA) is a laboratory-based special analysis service that monitors parameters of piston underside oil. CSDOA is not only able to identify cold corrosion of cylinder liners and provides early warning for the chief engineer but also contributes to the optimisation of cylinder oil feed rate and hence contributes as well to costs control.

3 A sophisticated analysis service allowing monitoring the condition of the main engine s cylinder liners

4 UNIMARINE MARINE ENGINES CYLINDERS SCRAPE-DOWN OIL ANALYSIS (CSDOA) FEATURES & BENEFITS FEATURES UNIMARINE COMMITMENT IS TO PROVIDE EXCELLENCE IN SERVICE AND COST EFFICIENCY IN VESSELS LUBRICATION BY OFFERING OPERATIONAL SOLUTIONS TO SHIP OWNERS AND MANAGERS Identifies cold corrosion of cylinder liners. Provides early warning to the chief engineer and the technical department. Provides comprehensive data on cylinder and rings operation. Monitors wear condition of cylinder and rings. Contributes to the optimization of cylinder oil feed rate. Monitors condition of stuffing box. Identifies contaminants (e.g. water and system oil). Avoids over-lubrication of the main engine. Monitor operating condition of the cylinder oil lubricant. BENEFITS Cold Corrosion in Cylinder Liners Allows considerable saving by focusing on preventive actions instead of costly corrective maintenance. Minimises unscheduled down time of main engine. Provides early warning before scheduled maintenance of main engine. Optimizes operating condition of modern main engines in order to reach safely desired load and speed requirements. Extend components life.. Allows real and safe optimization of cylinder oil feed rate. Minimises contamination of system oil of main engine by monitoring stuffing box condition (leakages). Reduces potential renewal of system oil by monitoring contaminants. Minimises wear of cylinder and rings as a result of ensuring proper heat transfer process between the piston and cylinder liner. Overall reduces operational costs.

5 Unimarine Cylinder Scrape-Down Oil Analysis (CSDOA) monitors cylinders condition to extend the lifetime of your engines key parts and reduces the operating cost of your fleet

6 A COMPLETE PICTURE OF THE CONDITION OF CYLINDERS LUBRICANT PARAMETERS Viscosity at 40 C Viscosity at 100 C Viscosity Index Soot Content Flashpoint Water Content Total Basic Number Ferrography (PQI) Viscosity is the single most important property of a lubricating fluid. The equipment will not perform as designed unless the lubricant is of the specified viscosity. Soot results from the incomplete combustion of the fuel and oxidation of the Lubricant, it contributes to deposits such as carbon and sludge and also leads to a viscosity increase. Flash point is indicative of potential fire hazard. Provides information on the relative volatility of the oil, which may be important in high temperature applications. Water is highly undesirable in most lubricating oil applications and should not normally be found in most systems. BN is used to follow lubricant depletion and degradation in service. The BN additives combine with acidic combustion by-products in order to neutralize them to avoid corrosion, resulting in a depletion of the additive in the oil. - Early indications of cylinder scuffing before seizure. - Metal fatigue of highly stressed surfaces. - Cutting and corrosive wear particles. Wear : Iron (Fe) Copper (Cu) Aluminium (Al) Tin (Sn) Lead (Pb) Molybdenum (Mo) Nickel (Ni) Chromium (Cr) Titanium (Ti) Silver (Ag) Contaminants : Lithium (Li) Vanadium (V) Sodium (Na) Boron (B) Potassium (K) Silicon (Si) Additives : Magnesium (Mg) Calcium (Ca) Antimony (Sb) Barium (Ba) Zinc (Zn) Phosphorus (P) ELEMENTS ANALYSIS CSDOA target is to measure the quantity of each WEAR METAL present at the bottom of the cylinder hence determining indications of cold corrosion. Wear metals may be present as oxides, metal soaps or metal fines. The results of CSDOA need to be interpreted studying the TREND for each considered wear element in order to take preventive actions in case of abnormal wear. Additive metals (generally calcium, magnesium, phosphorus, sulphur and/or zinc) need to be differentiated from Wear Metals as should be identified Contaminants generated by leakage from the stuffing box. LUBESAFE CSDOA REPORT

7 Interpreting the CSDOA Wear analysis results Trend is the key to control cold corrosion impact TREND ANALYSIS UNIMARINE CYLINDER SCRAPE-DOWN OIL ANALYSIS (CSDOA) needs to be implemented over a considered period of time in order to monitor closely the condition of cylinder liners, rings and Bearings and study the results as a Trend to allow the Technical Department and the Chief Engineer to timely take preventive actions thus reducing costs and down time. LUBESAFE Engineers are providing training on the interpretation of CSDOA results trend on board and on shore. SAMPLING FREQUENCY Analysis of samples should be performed at least every 1,000 hours. SAMPLING LOCATION TESTS Iron Copper Chromium PQ Index Phosphorus BN Depletion Water Soot PROBABLE CAUSES Wear (liners, rings, fuel pump, valves) / liner corrosion Wear (liners, stuffing box) Wear (rings, liners) / liners corrosion Wear condition Contamination with system oil Sulphur in fuel Leak in cooling system Poor combustion / Defective injectors, bad atomization / Excessive blow by & wear due to worn & stuck rings / Defective air input RECOMMENDATION ACTIONS Check the oil feed rate in operation and increase frequency of sample analysis Check the oil feed rate in operation and frequency of sample analysis / check maintenance of the stuffing box. Check the oil feed rate and increase frequency of sample analysis Check the oil feed rate in operation and increase frequency of sample analysis Check the maintenance of the stuffing box Check the oil feed rate in operation and increase frequency of sample analysis Check the maintenance of the cooling system Check the maintenance of injectors, rings, etc

8 rg bu am H WHO ARE WE? At the core of Shipping, UniMarine provides the maritime industry with tailor made, marine lubricants supply solutions and technical services the world over. We are a member of United Shipping & Trading (USTC), a global group of companies serving the marine market since 1876 as well as a renowned ship-owner and a global leader in marine bunkering. The UniMarine expert team is innovative and forward thinking in the field of marine lubrication while focused on our core values of trust, service, reliability and long-term commitment to serve the Shipping Community. It is all about Shipping! CONTACT OUR MARINE LUBRICANTS GLOBAL TEAM: marinelubs@unimarine-lubricants.com Singapore: United States (NYC): United States (Toll Free): UNI LUBE ( ) Germany (Hamburg): +49 (0)