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Bunker SummitGreece 2007
SEA-Mate™ Analyser and Blender
May 11 - Session 6: Under The Spotlight:
New Technologies and innovation in the bunker sector
12:10 – 12:20
Terry Robinson
Web: http://www.maerskfluid.com/
Email : [email protected]
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Maersk Fluid Technology-
Business & Marketing Plan 2007
(Draft)
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The Challenge
• Usage of rotating machinery in marine environments has grown exponentially over the past 30 years – there are about 45,000 vessels in operation, ~ 5,800 being Container Vessels …
– Tramp Freighters Liner Freighters Container Vessels
– Off-shore exploration / production platforms
– Oil & Gas supply vessels
– FPSO
– Crude, Gas and Product Tankers
• Ever growing fleet of marine vessels providing transportation of goods in a global economy …
• Crew size – availability of man-power …
• Ever more complex technologies involved …
• Growing environmental awareness / concerns …
• Rapidly growing costs – both capital and operational expense:
– “Daily Running Cost” biggest metric on the deep blue seas …
– #1 cost factor = fuel
– #2 cost factor = lubricants
– #3 cost factor = maintenance
PAGE 4May 11, 2007Maersk Fluid Technology, Inc.
The Challenge Cont..
• Heavy Fuel Oil
• Specification issues include:-
• Density, Viscosity, TSP, CCR, Flashpoint, Water , H2S, cat fines, Sulfur
• Sulfur content in SECA (Sulfur Emission Control Areas)
• Operational constraints in waiting for sample results if specifications are marginal.
• Speed of Bunkering V de-bunkering of out of spec Fuel (i.e. Sulfur marginally higher than 1.5% or cat fines above 80 PPM)
• Monitoring of filter / Separators to ensure removal of cat-fines
• Main Engine System Oil
• Contamination (from Stuffing box)
• Decreased fuel efficiency with increased contamination.
• Cylinder Oil (Two Stroke)
• Need for varying TBN based on HFO Sulfur content
• i.e. if HFO S=low then waste of BN and possible ring deposits
• Wear related to Cylinder Feed rates
• Hydraulic Oils and other Lubricants
• Base line and wear trending
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The Solution
• Optimize use of hydrocarbons on-board / -site equipment:
– reduce consumption of fuels and lubricants
– improve the environmental impact
– optimize lubricant formulation / cost-engineer lubricant performance
• Introduce tools to enable Predictive Maintenance and Incipient Failure Detection:
– near real-time analyses of hydrocarbons to assess equipment health
– apply artificial intelligence to analyze / fingerprint scenarios
– enable state-of-the-art data communication pathways to enable on- and off-board interpretation, analysis and product procurement: Remote Monitoring & Diagnostics
• Introduce the SEA-Mate™ line of products:
– on-board / -site analyses of elemental concentration in hydrocarbon fluids
– on-board / -site analyses of water contamination in hydrocarbon fluids
– on-board / -site analyses of other critical components: sulphur, cat-fines, monomers, asphaltenes, viscosity, density, heat content, etc.
– On-board/ -site blending of lubricants and fuels as operating conditions and product availability dictate
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Normal Operation …
Engine Technology: issues …
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Low BN cylinder oil /High-S fuel …
Engine Technology: issues …
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high BN cylinder oil /low-S fuel …
Engine Technology: issues …
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… and then there are all other hydrocarbons that require close monitoring …
stern tube oil
stern thrusterhydraulic oils
bow thrusterhydraulic oils
ancillary equipment:gear oils, hydraulic fluids, etc.
ME cylinder oil
ME system oil
TP engine oil
heavy fuel oil
marine distillate fuel
Liner Vessel 101 …
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• Elemental Analysis System:
– Simple, accurate and efficient on-board/-site testing of heavy fuel oil (HFO) before it comes on-board for Sulphur (± 0.01%) and cat-fines down to protection limit in less than 10 minutes.
– Quality Testing of HFO for waste oils etc.
– Engine Wear Characteristics of scrape-down samples with the following elements: Calcium, Vanadium, Chromium, Iron, Nickel, Copper, Zinc, Barium, Lead and Phosphorus.
– Simple-to-understand user interface, which includes use of bar-code reader for logging a) time, b) sample location, c) sample fluid / associated specification for quality control, and d) sample bottle ID, removing errors via manual input
Fast and Simple
May 11, 2007Maersk Fluid Technology, Inc.
SEA-Mate™ Analyzer
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• Non destructive testing of samples,
• Simple bar code system to pair Sample
locations with unique sample bottle ID’s,
• Specification limits are pre-assigned to
location ID’s,
• Traffic light (Green / Amber / Red) sample
results against specifications,
• Comparative trending of results,
• Password security with full results and time
stamped traceability,
• Based on open standards communications
for future proofing,
• Possible communications with other
onboard systems for comparative trending
(engine load, speed, humidity, etc),
• Enterprise communications protocol for
possible business system integration,
• Artificial intelligence model capability for
data processing and pattern matching
SEA-Mate™ Analyzer
Fast and Simple user interface
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Status:
• Gen-II:
– Demonstration of commercially available system to both internal and external parties has yielded large interest from both OEMs and maintenance specific companies
– Maersk Oil & Gas, Maersk Contractors, MAN B&W, Wärtsilä, Mitsubishi Heavy Industries, Vestas, and DONG / Energi2
– Field Trials:
• Presently 10 × SEA-Mate™ Gen-II Analyzers installed on-board vessels and a Power Generation
Barge in Mindanao with very encouraging results
• fully updated Gen-III SEA-Mate™ to be used with Blender trial on „Sine Maersk‟• Gen-II SEA-Mate™ deployed on Power Barge PB-118 to support SEA-Mate™ BoB-trial.
• Gen-III:
– to be included with all Blending-on-board installations
– includes capability to analyze cat-fines down to 5 ppm for bunkers
– first prototype to be available by 2Q´2007,
vessel trial to begin 3Q‟2007
SEA-Mate™ Analyzer
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Lab correlation + Gen-3
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• SEA-Mate™ Blender:
– tool to provide on-board / -site blending of optimized fluids, namely main engine cylinder oil from used system oil to increase operational flexibility and reduce daily running cost
– blends fluids of widely different physico-chemical characteristics to consistent, high-performance lubricant specifications
– Delivers tailor-made lubricants to meet the demands of the vessel and fuel
• Why use used system oil?
– Constant replenishment of system oil leads to improved system oil condition:
• Reduces cooling bore deposits
• Improves main engine bearing lubrication
• Improves engine efficiency
• Reduces waste
Optimised Fluid Solutions
SEA-Mate™ Blender
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SEA-Mate™
Blender
SEA-Mate™ Blender - Layout
Sludge Tk. ME Sump Clean Tk. Add. Tk.
Hold. Tk.
Day Tk.Lubricator
Main Engine
Fuel
Cylinder Oil
Fresh
System Oil
Scavenge OilUsed
System OilAdditive
Emissions
SEA-Mate™
Analyser
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SEA-Mate™ Blender - installed
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• SEA-Mate™ Blender:
– Presently 2 × SEA-Mate™ blenders installed on-board „Sine Maersk‟ and PB-118
power Barge in Mindanao, Philippines
– In addition, off-board blending continues to be tested on „Caroline Maersk‟
– MAN B&W evaluation / comparison of commercial cylinder lubricants vis-à-vis
blended cylinder oil, prove performance even in part superior to commercial grades
– Blender re-design to reduce costs, improve reliability, operations and installations to
be completed by end of 2006, with prototypes to become available by May 2007
– Installation of next generation blenders on A.P. Moller Maersk container fleet to
begin Q2 2007
– A second series of trials will investigate the feasibility of blended oil solution to
allow running on low and zero sulphur fuels in environmentally sensitive areas
SEA-Mate™ Blender Status
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• Several design options available dependent on requirements
• SEA-Mate™ Blender - Key features:
• Blended oil properties are PLC controlled
• Mass flow meter or volume flow meter options available
• Capable of blending range of fluids
– Base oil feed stream up to 1735cSt @5oC
– Additive feed stream up to 100,000+cSt @5oC
– Typical finished fluid for HFO operation *
» TBN range 35-80mgKOH/g
» Viscosity typically 16.5cSt (figure dependent on feed streams)
• Volumes up to 2.5m3/hour possible
• Classification bodies approvals
• ABS approval granted for several Maersk vessels
• Discussion ongoing with other classification bodies
• Approval granted on a per vessel basis
• Pre-Type approval – next generation prototypes approved by ABS and Lloyds Register
• Type approval design in progress
SEA-Mate™ Blender Features
* TBN and viscosity range is dependent on feed streams used. For LSFO alternative additive technologies can be introduced
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OEM Approvals
•Negotiation with OEM‟s regarding blended oil specification and approvals underway with the following proposals received:
•The blender unit must as a minimum fulfil the following requirements for the blended product:
o TBN min. 40, ASTM D2896o Stable TBN (± 2 mgKOH/g), ASTM D2896o Stable viscosity (± 2%, SAE50), ASTM D445
o Oil stability (no precipitation after one month storage)o No abrasive particles, e.g. sand, dust etc, ICP/XRF measurementso Water: max 0.2%, ASTM D1744o Flash point: min. 1900C, ASTM D93o TAN: 0 mgKOH/g, ASTM D664
•These properties must be tested in an independent lab, and each test result verified by at least two samples taken at the same time.
