sea-mate™ analyser and blender -...

PAGE 1

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 : CPHMFTMKT@maersk.com

PAGE 2

Maersk Fluid Technology-

Business & Marketing Plan 2007

(Draft)

PAGE 3

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

PAGE 5

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

PAGE 6

Normal Operation …

Engine Technology: issues …

PAGE 7

Low BN cylinder oil /High-S fuel …

Engine Technology: issues …

PAGE 8

high BN cylinder oil /low-S fuel …

Engine Technology: issues …

PAGE 9

… 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 …

PAGE 10

• 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

PAGE 11

• 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

PAGE 12

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

PAGE 13

Lab correlation + Gen-3

PAGE 14

• 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

PAGE 15

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

PAGE 16

SEA-Mate™ Blender - installed

PAGE 17

• 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

PAGE 18

• 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

PAGE 19

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.

PAGE 20

Thank you!

Web: http://www.maerskfluid.com

Email : CPHMFTMKT@maersk.com