Zainudin Yahya

Business Development Manager

Condition Monitoring AsiaEmail: zainudin.yahya@parker.com

Evolution of Condition Monitoring

Parker Kittiwake

Backed by the power of Parker!

• Parker Kittiwake - The world

leader in onboard/online oil & fuel

condition monitoring

• Comprehensive product range for

testing & monitoring bunker fuels,

lubricant, scrape-down oils and

water

• Based near Southampton &

Portsmouth, UK

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Global Partners

Used across the worlds by oil companies, engine

OEMs, naval forces, shipping companies, offshore

contractors, power generators….

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Onboard testing = Faster results

• Tests performed onboard

• Results within minutes

• Higher specifications,

higher accuracy

• Powerful data analysis

tools

• Faster response times

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Products

DIGI Kits - Economical testing

• Viscosity Comparisons

• Water in Oil (+/-200ppm)

• TBN/TAN

• Insolubles (qualitative)

• Salt water test (No/No Go)

Oil Test Centres

• Viscosity, WIO, TAN, TBN, Insolubles

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Products

Comprehensive supplier

• Compatibility Oven

• Flash Point Tester

• Cloud Point Tester

• (Add here)

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Market demand, drives towards

online Condition Monitoring (CM)

• Class Societies encourage online CM - extends

period of certain 5-year survey items

• Proven: 60% of marine mechanical failures are

caused by human intervention

• Crews today have less experience of operating

machinery and its overhaul. Makers men are

increasingly used, exacerbating the problem

• Higher risks of quickly developing fault trigger

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Main engine – costly fault triggers

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!

• Trigger 1: Over/under lubricating = liner wear

• Trigger 2: Slow steaming = corrosive liner wear

• Trigger 3: Low sulphur fuel = catalytic fines induced

abrasive wear to piston & liner

• Trigger 4: Rough sea and a rolling moment may stir up

settled Cat fines in the daily service tank

Trigger 1: Optimised CLO feed rate

Over Lubricating:

• Increases wasted oil

• Build-up on cylinder rings

Under Lubricating:

• Scuffing – liner and rings

MAN B&W “Optimisation of CLO feed rate is necessary. Over-

lubrication increases abrasive wear.”

Wartsila-Sulzer “High cylinder oil feed rate can cause deposit build-

up, causing abrasive wear. Too low, also causes abrasive wear and

corrosive wear.”

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Calcium build up on Piston

Trigger 2: Slow Steaming Corrosive

Wear

• Slow steaming saves fuel

• The lower temperatures

cause sulphuric acids to

build up in the post

combustion process

• If not identified and the

correct action taken can

cause corrosive wear

• CCTK identifies and

allows corrective action

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Corrosion on Liner

Trigger 3: Catalytic Fines

• Low sulphur fuels are produced

using “catalytic hydrocracking”

using Aluminium Silicate (Al + Si)

catalyst to boost sulphur removal

• ISO 8217:2010 fuel standard

allow for Al + Si up to 60 ppm

• But OEM recommend maximum

of 15ppm!

• Particles are almost as hard as

diamond and abrasive.

• Cat fines will cause severe wear

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Abraded Liner Surface

Wear debris - piston rings

Trigger 4: Rough seas and rolling

movement

• DNV reported in 8-10 Dec 2010

• Despite having fuel separators,

filters and fuel on specifications, it

was found that during rough seas,

settled cat fines, stirred up and

co-mingle in a quantity above the

capacity of centrifuge separation

and filtration

• Within less than 100 hours -

engine worn out

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Cat fines wear

Triggers = damage = expensive

• Cylinder liner & piston

damaged are common

engine claims costly

repairs

• Repair cost >USD500K

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Cat fines wear

24/7 Liner Wear Monitoring Solution

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Initial driver was CLO savings

• CLO savings = Current expenses on CLO x % savings

• Lowest reported with LinerSCAN is 0.6g/Kwh

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LinerSCAN – Raising a timely alarm

• 2010-13, MDT’s PrimeServ

reported 190 cases of liner wear

due to Cat fines > 50 cases/year

• 1.5 year study with K98ME MAN

B&W engine, which was monitored

with LinerSCAN

• LinerSCAN clearly identified the

moment abnormal liner wear was

triggered on 6 January 2011

• Various degrees of liner wear can

be monitored as it happened, from

low average below 200ppm, to mild

attack averaging at about 250ppm

and severe attack averaging at

above 1,000ppm

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Data from CIMAC Congress 2013: P51

LinerSCAN – Provides the

opportunity to prevent damage

• Under a controlled environment,

tank cleaning and improved

cleaning was done on 8th May

almost 4 months after the Cat fines

triggered wear began

• Within days LinerSCAN reported a

drop in wear rate to about 250ppm,

then after 6 days settled at below

200ppm

• LinerSCAN enables real-time

monitoring of liner wear!

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Data from CIMAC Congress 2013: P51

LinerSCAN References

• >300 sensors installed

• MAN B&W, Wartsila-Sulzer, MITSUI NYK,

Hanjin, MSC, CSAV, OOCL, Matson

• A.P. Moller Maersk: “Lubricating at lower

levels means an increased risk to liner,

however this can be mitigated by using

LinerSCAN.”

• Reederei F. Laeisz: “We’ve found the

LinerSCAN particularly useful for reducing

the risk of high wear in unfamiliar

environments.”

• Matson. “By monitoring the scrape-down oil

for ferrous wear, LinerSCAN can enable

immediate action.”

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Conclusions

• LinerSCAN originally offline tool to save CLO,

evolved to on-line with increased utility: CLO, damage

prevention, wear monitoring.

• Parker Kittiwake continue to develop new solutions to

meet customer demands with other solutions such as

• WaterSCAN – detects water contamination in

lube oil systems.

• ThrusterSCAN – detects metallic wear in

lubricated gear system such as thrusters.

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