getting it right: a ship operator’s perspective on...
TRANSCRIPT
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Bunker SummitGreece 2007
Getting it Right:
A Ship Operator’s Perspective on Lubricants
May 10 - Session 4: Choosing the right fuel testing and Lubricants 15:20 – 15:40
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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VISION & MISSION
Vision:
• Maersk Fluid Technology (MFT-I) will provide best-in-class, cost-effective and technologically leading solutions for APM clients‟ lubrication needs.
• In addition, MFT-I will initiate, create, secure and commercialize innovative and cost-effective fluid solutions focusing on internal APM clients needs, while also offering these to select external parties.
• MFT-I above vision represents what MFT-I Managements will strive to achieve through the combined efforts of MFT-I employees as well as industry specialists.
Mission:
• Creating a Fluid Technology platform, that allows the end-user to focus on quality and quantity of products procured, expended, and transported, thereby enabling end-users to make well-informed decisions on the basis of near-real time fluid tests, in turn improving operational efficiency and lowering Total Cost of Ownership, hence increasing profitability
• Blending Cylinder Oil on-board, variable to S-content of fuel and engine make/model, also to reduce fuel consumption, extend engine component life and reduce emissions and waste.
• Streamlining processes, improved stock controls, simplified procedures and pricing structure
• Developing performance standards to allow for the use of multiple formulations per supplier and developing on system oil, cylinder oil and blend-on-board solutions utilising Group II/III base oils
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Scope of business:
• Procurement & Technology
• Lubricants to APM-M clients on a global scale
• SEA-Mate™* product line (Analyzer, Blender, Liquid Separation, Emissions Abatement, Next Generation Lubricants and Vendor-Managed Inventory)
For what markets ?
• Marine
• Oil & Gas – Upstream: Exploration & Production
• Power Generation
With what competitive advantage ?
• Operational flexibility, preventative maintenance, improved supply security, resulting in reduced overall Daily Running Costs and Total Cost of Ownership
• Intellectual Property
* APM-M registered trademark for the product line, including and surrounding Blending-on-Board and Analyzer.
SCOPE & OBJECTIVE
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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 6May 10, 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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up to 430 m Length × 56 m Beam × 70+ m overall Height × 30 m Depth Molded × 16 m Draft
25 kts sustained speed
14,000 TEU (20 foot container equivalent units) capacity
Single-screw, direct drive propulsion
Bow and Stern Thrusters to add port maneuverability
Crew of 13
Original cost well in excess of US-$ 120MM
Powered by 14 cylinder, slow-speed, 2-stroke, in-line, cross-head diesel engine from Wärtsilä
in-line engine rotating at 65 – 105 rpmup to 10,000 bhp / cylinder power outputexhaust heat recovery with exhaust turbines and electric shaft drives~ 180 g / bhp hr fuel consumption at 75% load = 118,000 MT p.a.~ 0.85 g / bhp cylinder lube consumption = 560 MT p.a.
Fuel: HFO and MD; Lubricants: 50+ grades
… the heart of today‟s global logistics: Maersk Line‟s PS-Class vessels …
Liner Vessel 101 …
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… two types of Diesel Engines are used in Marine, O&G and Power Gen applications …
2-stroke, large bore, long to ultra-long stroke,cross-head, slow-speed engines …
4-stroke, medium bore, medium trunk piston engines …
… the classic, highly fuel-efficient propulsion engine … the engine of choice for auxiliary power or size-constrained vessels, e.g. Ro-Ro, car carriers, supply vessels, etc.
Engine Technology 101 …
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… in addition there are heavy-duty medium speed diesel engines, gas turbines …
NG / Dual-Fuel Aeroderivative or HD-IndustrialGas Turbines …
… the light-weight, small footprint solution widely used in Oil & Gas applications.
… however, the ‘workhorse’ remains the slow-speed, 2-stroke engine, largely due to its unrivaled fuel efficiency!
Then again, there are multiple inherent problems and complexities,illustrated in the following slides …
Engine Technology 101 …
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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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Rule #1: so called „heavy fuel oil‟ is matter of fact the „bottom of the barrel‟ out of any refinery …
Rule #2: it is still the single most expensive commodity used in shipping!
While probably the „dirtiest‟ fuel legally available today, it offers a high heat content and can be burnt almost stoichiometrically in large-stroke diesel engines – only exceeded by Orimulsion® or coal dust for that matter!
While – based upon tonnage transported – marine freight offers by far the most environmentally friendly means of mass transportation, the fuel used still poses great challenges for environmentally concerned operators such as Maersk Line: i.e. fuel specifications, regarding S, V, or any heavy metal content, cat-fines, any organic contaminants, etc. must be closely monitored and where out-of-specification, must be rejected prior to bunkering …
… why? A modern vessel can load fuel at up to 2,500 MT per hour … - however, it can only de-bunker at a rate of about 500 MT / hour …
Most critical fuel parameters:
• Elemental content: S, V, Na, Cl, Si + Al (for detection of cat-fines), as well as any heavy metals …• Water …• Heat content …• Hydrocarbon contaminants: asphaltenes, monomers (e.g. styrene), waste oil …• Density, flash point, viscosity …
… and then there is Fuel …
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At the beginning of 2006 APM Innovation, LLC was formed as an intellectual property holding firm to allow its members to collectively benefit from patents and trade secrets developed and ensure A.P. Møller-Mærsk of access to developed SEA-Mate™ technology over the typical life of vessels and Oil & Gas equipment …
At present APM Innovation, LLC includes members
Maersk Fluid Technology, Inc. as both end-user as well as marketing & sales entity to external users …
Innov-X Systems, Inc. as provider of analytical equipment …
KODDI Systems, Inc. as provider of blending equipment …
Furthermore, TEEDRO, Ltd. To be added as a 4th member providing vital information technology knowledge …
… so what are the products so far developed?
… Strategic partnerships …
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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 10, 2007Maersk Fluid Technology, Inc.
SEA-Mate™ Analyzer
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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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• 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:
– 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 at least equivalent to current 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
