HANS JENSEN LUBRICATORS A/S

Transcription

1 HANS JENSEN LUBRICATORS A/S Case study Cylinder oil consumption on Sulzer RT-flex engines Example of reduction in cylinder oil consumption on: Sulzer 7RT-flex68-B & Sulzer 12RT-flex96C Innovation through generations Disclaimer: The data contained in this document serves informational purposes only and is not guaranteed in any way. Depending on specific individual projects, the relevant data may be subject to changes - depending on the characteristics of each individual project, especially specific vessel, engine type and operational conditions.

2 SUMMARY Our findings in this case study points towards a substantial over consumption of cylinder oil on Sulzer RT-flex engines. There is potential for optimizing maximum cylinder liner wear by applying an optimal cylinder lubrication solution. There is potential for a significant reduction in cylinder oil consumption by optimizing feed rate (in relation to engine and cylinder condition).

3 THE ENGINES Sulzer 7RT-flex68-B Engine: Hyundai-Wärtsilä 7RT-flex68-B Max output: 21,490 kw Sulzer 12RT-flex96C Engine: Hyundai-Wärtsilä 12RT-flex96C Max output: 68,640 kw Sulzer RT-flex96C

4 CONTENTS Purpose The solution: HJ Lubtronic SIP Savings Calculation and Cash Flow for 7RT-flex68-B & 12RT-flex96C Quotations Installation and project timeline Feed Rate Optimization Program Operational Experiences from Sulzer engines Conclusion

5 PURPOSE Cylinder lubrication upgrade To reduce wear on liner and piston rings Potential less use of spare parts To gain substantial savings on cylinder oil consumption = Lower running costs for vessels The solution HJ Lubtronic SIP

6 THE SOLUTION HJ Lubtronic SIP Optimized distribution and injection of cylinder oil Ensures a uniform and stable oil film which reduces wear Savings on cylinder oil Optimum feed rate setting

7 HJ LUBTRONIC Purpose Electronic engines created the need for electronic lubrication and intelligent lubrication system control independent of the crew Improve cylinder condition (reduce max. wear) Cope with slowsteaming Fight cold corrosion Automatic adjustment acc. to load Easy operation Reduce OPEX Lubricators Injection valves Lubrication system

8 HJ LUBTRONIC Key features Injection of fresh oil with every engine revolution Patented Also at low load operation Maintain stable oil film Central computer operation Lower CLOC due to aut. algorithm control Optional features Automatic regulation acc. to sulphur Total flowmeter with software integration Individual alarm integration Lubricators Injection valves Lubrication system

9 CLASSIFIED HJ LUBTRONIC System Layout Cyl. 2 Cyl. 1 Fly wheel Pressure: 6 bar Lube oil Supply OPTION: Signals for RPM/Rotation direction RPM + Rotation direction signals Alarm signals Alarm Merger Network cables Pressure: 70 bar Alarm signals to Alarm Merger Hydraulic Pump Unit Engine Interface (Control room / Engine room) Index Pickup Local Cylinder Controller Local Cylinder Controller Computer Interface OPTION: Power/ Fuel Index Lubricators Injection valves Lubrication system

10 HJ LUBTRONIC Automatic system ensures correct feed rate Easy to use equipment Automatic adjustment of feed rate acc. to load (and optionally sulphur) Central operation done on computer or locally setup Reliability Redundancy system backup Less maintenance Potential less use of spare parts Lubricators Injection valves Lubrication system

11 HJ LUBTRONIC Installation pictures 7RT-flex68 Lubricators Injection valves Lubrication system

12 HJ SIP Key features Injection of cylinder oil above the piston Patented distribution on the cylinder liner wall by means of the scavenge air swirl Uniform distribution in top of liner also on super long stroke engines Effectively fights the sulphuric acids Reduces risk of cold corrosion Only one grade of cylinder oil required Minimum blow-off-oil-spill (to under piston space) Lubricators Injection valves Lubrication system

13 HJ SIP Purpose and advantages of HJ SIP lubrication Cylinder oil distributed by piston = Unequally distribution Traditional Cylinder oil distribution system Cylinder oil injection before piston passes = Thin & uniform oil film HJ SIP Cylinder oil distribution system Lubricators Injection valves Lubrication system

14 HJ SIP Traditional vs HJ SIP vs Intermittent The result of HJ SIP Lubrication is a stable, even oil film which protects the cylinder liner and piston and ensures an optimal cylinder condition. Traditional (left) injects cylinder oil at every revolution but uses piston rings for distribution. Intermittent (right) injects cylinder oil once at upto engine revolutions (at low load operation), and uses the piston for distribution. The result is increased wear as the oil film becomes uneven, worn down and there is not enough base (alkalinity) to neutralize acids (e.g. cold corrosion). View this animation on our website Lubricators Injection valves Lubrication system

15 HJ SIP Wear in top of the liner HJ SIP lubrication / distribution of CLO offer the potential to reduce wear both abbrasive and corrosive Lubricators Injection valves Lubrication system

16 HJ SIP Based on actual operational data Wear profiles indicates trumpet-shape Lubricators Injection valves Lubrication system

17 HJ LUBTRONIC SIP Two superior systems working together HJ SIP (injection valves) Optimal distribution of CLO results in improved cylinder condition and a massive savings potential is present. Manual adjustment is required to realize the potential. HJ Lubtronic (electronic lubricator) Using HJ Lubtronic the lowest possible feed rate is automatically obtained. Crew intervention needed is kept at a minimum. HJ Lubtronic SIP HJ Lubtronic SIP offers the lowest possible feed rate with the best possible cylinder condition. Lubricators Injection valves Lubrication system

18 SAVINGS CALCULATIONS EXAMPLES Sulzer 7RT-Flex68B & Sulzer 12RT-Flex96C

19 SAVINGS CALCULATION Sulzer 7RT-flex68-B Yearly estimated savings more than EUR 85,000 Before change to HJ Lubtronic + SIP: Cylinder oil price: 65% load = liter/day USD/liter. Running hrs. pr. year: 6,000 After change to HJ Lubtronic + SIP: Savings: actual load (65%) = liters pr. day liters liters = liters pr. day liters(212.8/24)/hr X 6,000 r. hrs. X 2.10 USD/liter(/1.30 EUR)= 85,970 EUR/year

20 SAVINGS CALCULATION AT TARGET FEED RATE Sulzer 7RT-flex68-B Target feed rate (g/kwh) Savings per year (EUR) , , , ,000 Basis for calculations Before change to HJ Lubtronic SIP: Feed rate: 1.20 g/kwh Average load: 65% Running hours: 6,000 Cylinder oil price: 2.1 USD/liter

21 CASH FLOW HJ Lubtronic SIP - Hardware AND Est. installation + liner machining Break even in 2.59 years Target F/R 0.6 g/kwh Cash flow - net cash payment Months Expense Accumulated saving Cashflow , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , ,00 *Above calculations are based on assumed specification of hardware and engine condition and are subject to change, if any, based on final specification.

22 QUOTATION Sulzer 7RT-flex68-B HJ Lubtronic SIP incl. all necessary hardware: *EUR 163,159 Spare parts for HJ Lubtronic SIP incl. one mandatory spare lubricator: *EUR: 7,815 Estimated installation costs: **EUR 40,000 Estimated costs for cylinder machining: EUR 12,000 *Above prices are based on assumed specification of hardware and are subject to change, if any, based on final specification. **Above prices does not include waiting time and travel expenditures for service engineer(s) and packing of product.

23 SAVINGS CALCULATION Sulzer 12RT-flex96C Yearly estimated savings more than EUR 168,000 Before change to HJ Lubtronic + SIP: Cylinder oil price: 40% load = liter/day USD/liter. Running hrs. pr. year: 6,000 After change to HJ Lubtronic + SIP: Savings: actual load (40%) = liters pr. day liters liters = liters pr. day liters(418.02/24)/hr X 6,000 r. hrs. X 2.10 USD/liter(/1.30 EUR)=168,815 EUR/year

24 SAVINGS CALCULATION AT TARGET FEED RATE Sulzer 12RT-flex96C Target feed rate (g/kwh) Savings per vessel per year (EUR) , , , ,120 Basis for calculations Before change to HJ Lubtronic SIP: Feed rate: 1.20 g/kwh Average load: 40% Running hours: 6,000 Cylinder oil price: 2.1 USD/liter

25 CASH FLOW HJ Lubtronic SIP - Hardware AND Est. installation + liner machining Break even in 1.83 years Target F/R 0.6 g/kwh Cash flow - net cash payment Months Expense Accumulated saving Cashflow , , , , , , , , , , , , , , , , , , , , , , , , ,00-90, , , , , , ,00 *Above calculations are based on assumed specification of hardware and engine condition and are subject to change, if any, based on final specification.

26 QUOTATION Sulzer 12RT-flex96C HJ Lubtronic SIP incl. all necessary hardware: *EUR 222,035 Spare parts for HJ Lubtronic SIP incl. one mandatory spare lubricator: *EUR: 7,815 Estimated installation costs: **EUR 60,000 Estimated costs for cylinder machining: EUR 20,000 *Above prices are based on assumed specification of hardware and are subject to change, if any, based on final specification. **Above prices does not include waiting time and travel expenditures for service engineer(s) and packing of product.

27 INSTALLATION Working hours: Sulzer 12RT-flex96C: *465 (Approx.) Sulzer 7RT-flex68-B: *300 (Approx.) Most work can be done while sailing (setting up lubricators, piping, etc.). When installing HJ SIP valves and switching to HJ Lubtronic SIP the vessel needs to be immobilized for up to 48 hours (alternatively 2 x 24). Time also depends on how much help our Service Engineers can get from vessel crew. As it is a Sulzer Flex-engine Kongsberg needs to get onboard vessel before HJ in order to make signals from the engine available to our lubrication system. *Not including cylinder machining

28 PROJECT TIMELINE Month 1 Order Data collection Month 2 Production Month 3 Installation Feed Rate Optimization Program begins: 2-3 reports per year

29 FEED RATE OPTIMIZATION PROGRAM

30 FEED RATE OPTIMIZATION PROGRAM A two-part program consisting of Scrape Down Analysis and Port Inspection Report which offers the potential for: Improved cylinder condition Savings on cylinder oil Reduction in scavenge sludge Positive impact on exhaust emission and particles Early warning if any abnormal situations (eg. cold corrosion) Lubrication system Service Experience Hans Jensen Lubricators

31 Example ppm FEED RATE OPTIMIZATION PROGRAM Scrape Down Analysis Evaluate cylinder condition according parameters in used cylinder oil (eg. Iron, TBN) Catfines not detected in a timely manner is a very costly affair eg.: Replacement of liners and pistons Cleaning of entire system/tanks Shows changes in used cylinder oil condition Data can pinpoint specific cylinder issues and compare with general condition of engine 1600,0 1400,0 1200,0 1000,0 800,0 600,0 400,0 200,0 0, TBN Feb 6,2 7,8 8,3 4,4 6,0 4,3 TBN Mar 15,1 12,7 10,9 14,0 28,1 11,7 TBN Jun 44,3 45,9 42,5 41,8 43,5 41,9 Iron Feb Iron Mar Iron Jun Si+Al Feb Si+Al Mar Si+Al Jun Feb: Mar: Jun: Feed rates 0,4 g/kwh 0,5 g/kwh 1,0 g/kwh Lubrication system Service Experience Hans Jensen Lubricators

32 Example FEED RATE OPTIMIZATION PROGRAM Port Inspection Report Report evaluating and analyzing cylinder condition based on pictures from eg. piston skirt, liner wall and piston top land Possible to identify specific parts in good and poor condition Possible to identify abnormal situation e.g. poor combustion and water ingress Poor combustion will be visible at port inspection before visible in SDA Lubrication system Service Experience Hans Jensen Lubricators

33 FEED RATE OPTIMIZATION PROGRAM Based on a century of experience You will receive Detailed report with evaluations of cylinder condition, and recommendations on how to improve condition and feed rate Incl. eg. guide to adjustment of feed rate, guide to maintaining lubrication system, etc. 10 reports over a four year period Evaluations and recommendations based on both visible (PIR) and non-visible (SDA) parameters. As well as a century of experience within the field of cylinder lubrication for 2-stroke marine diesel engines Report example Lubrication system Service Experience Hans Jensen Lubricators

34 OPERATIONAL EXPERIENCES 7RTA58T - HJ SIP Data Installation date: 12/ ME running hours after HJ SIP installation: Feed rate before installation: Feed rate after installation: CLOC after installation 1,08 g/kwh 0,66 g/kwh 180 L/day Piston rings are in good condition. Minor combustion issues, but lubrication is adequate.

35 OPERATIONAL EXPERIENCES 7RTA72U-B HJ Lubtronic SIP PISTON SKIRTS Data Feedrate: 0,8 g/kwh Date: Clear signs of overlubrication lube oil is visible GOOD CONDITION FEW DEPOSITS Data Feed rate: 0,7 g/kwh Date: Improvement in lubrication less oil visible, with no signs of wear on skirt

36 OPERATIONAL EXPERIENCES 7RTA72U-B HJ Lubtronic SIP PISTON RINGS Data Feedrate: 0,8 g/kwh Date: Poor combustion potential overlubrication as there is wet and black oil on piston rings FINE CONDITION MARGINALLY WET Data Feed rate: 0,7 g/kwh Date: Signs of overlubrication, but not alarmingly so. Rings and ring-land are nice and clean.

37 OPERATIONAL EXPERIENCES 7RTA72U-B HJ Lubtronic SIP PISTON TOP Data Feedrate: 0,8 g/kwh Date: Signs of overlubrication -white/grey deposits on top. GOOD CONDITION Data Feed rate: 0,7 g/kwh Date: Adequate lubrication.

38 CONCLUSION HJ Lubtronic SIP Gain massive savings on cylinder oil consumption Reduce maximum wear on liner and piston rings = Reduce running costs HJ Lubtronic SIP offers Injection of CLO at every piston stroke Optimized cylinder condition Optimal CLO distribution Proven operational experiences Optimize your vessels feed rate and cylinder condition Take advantage of a century of experience in cylinder lubrication