Innovation through generations
HANS JENSEN LUBRICATORS A/S
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.
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
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).
SUMMARY
THE ENGINES
Sulzer 12RT-flex96C Engine: Hyundai-Wärtsilä 12RT-flex96C Max output: 68,640 kW
Sulzer RT-flex96C
Sulzer 7RT-flex68-B Engine: Hyundai-Wärtsilä 7RT-flex68-B Max output: 21,490 kW
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
CONTENTS
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
Cylinder lubrication upgrade
PURPOSE
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
HJ Lubtronic SIP
THE SOLUTION
Lubricators Injection
valves Lubrication
system
HJ LUBTRONIC
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
Purpose
Lubricators Injection
valves Lubrication
system
HJ LUBTRONIC
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
Key features
Lubricators Injection
valves Lubrication
system
Lube oil Supply
Hydraulic Pump Unit
Computer
Interface
Cyl. 1
Local Cylinder
Controller
Cyl. 2
Local Cylinder
Controller Index Pickup
Fly wheel
RPM + Rotation
direction signals
Alarm signals
Engine
Interface (Control room /
Engine room)
OPTION:
Signals for
RPM/Rotation
direction
OPTION:
Power/
Fuel Index
Alarm Merger Network cables
Pressure:
6 bar
Pressure:
70 bar
Alarm signals to
Alarm Merger
HJ LUBTRONIC System Layout
CLA
SSIF
IED
Lubricators Injection
valves Lubrication
system
HJ LUBTRONIC
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
Automatic system ensures correct feed rate
Lubricators Injection
valves Lubrication
system
HJ LUBTRONIC Installation pictures – 7RT-flex68
Lubricators Injection
valves Lubrication
system
HJ SIP
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)
Key features
Lubricators Injection
valves Lubrication
system
HJ SIP
Purpose and advantages of HJ SIP lubrication
Traditional
Cylinder oil
distribution
system
Cylinder oil distributed
by piston
= Unequally distribution
Cylinder oil
injection before
piston passes
= Thin & uniform
oil film
HJ SIP
Cylinder oil
distribution
system
Lubricators Injection
valves Lubrication
system
HJ SIP
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 15-20 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
Traditional vs HJ SIP vs Intermittent
Lubricators Injection
valves Lubrication
system
HJ SIP
HJ SIP lubrication / distribution of CLO offer the potential to reduce wear – both abbrasive and corrosive
Wear in top of the liner
Lubricators Injection
valves Lubrication
system
HJ SIP
Wear profiles indicates ”trumpet-shape”
Based on actual operational data
Lubricators Injection
valves Lubrication
system
HJ Lubtronic SIP
HJ Lubtronic
(electronic lubricator)
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.
Using HJ Lubtronic the lowest possible feed rate is automatically obtained. Crew intervention needed is kept at a minimum.
HJ Lubtronic SIP offers the lowest possible feed rate with the best possible cylinder condition.
HJ LUBTRONIC SIP Two superior systems working together
Sulzer 7RT-Flex68B & Sulzer 12RT-Flex96C
SAVINGS CALCULATIONS EXAMPLES
Sulzer 7RT-flex68-B
SAVINGS CALCULATION
Before change to HJ Lubtronic + SIP: 1.20g/kWh @ 65% load = 425.7 liter/day. Cylinder oil price: 2.10 USD/liter. Running hrs. pr. year: 6,000 After change to HJ Lubtronic + SIP: 0.6g/kWh @ actual load (65%) = 212.9 liters pr. day. Savings: 425.7 liters – 212.9 liters = 212.8 liters pr. day. 8.87 liters(212.8/24)/hr X 6,000 r. hrs. X 2.10 USD/liter(/1.30 EUR)= 85,970 EUR/year
Yearly estimated savings more than EUR 85,000
Sulzer 7RT-flex68-B
SAVINGS CALCULATION AT TARGET FEED RATE
Target feed rate (g/kWh)
Savings per year (EUR)
0.8 57,000
0.7 71,000
0.6 85,000
0.5 100,000
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
HJ Lubtronic SIP - Hardware AND Est. installation + liner machining –Break even in 2.59 years– Target F/R 0.6 g/kWh
CASH FLOW
*Above calculations are based on assumed specification of hardware and engine condition and are subject to change, if any, based on final specification.
Months Expense Accumulated saving Cashflow
0 -222.974,00€ -€ -222.974,00€
1 7.163,33€ -215.810,67€
2 14.326,67€ -208.647,33€
4 28.653,33€ -194.320,67€
6 42.980,00€ -179.994,00€
8 57.306,67€ -165.667,33€
10 71.633,33€ -151.340,67€
12 85.960,00€ -137.014,00€
14 100.286,67€ -122.687,33€
16 114.613,33€ -108.360,67€
18 128.940,00€ -94.034,00€
20 143.266,67€ -79.707,33€
22 157.593,33€ -65.380,67€
24 171.920,00€ -51.054,00€
36 257.880,00€ 34.906,00€
48 343.840,00€ 120.866,00€
Cash flow - net cash payment
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
Sulzer 7RT-flex68-B
QUOTATION
*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.
Sulzer 12RT-flex96C
SAVINGS CALCULATION
Before change to HJ Lubtronic + SIP: 1.20g/kWh @ 40% load = 836.4 liter/day. Cylinder oil price: 2.10 USD/liter. Running hrs. pr. year: 6,000 After change to HJ Lubtronic + SIP: 0.6g/kWh @ actual load (40%) = 418.38 liters pr. day. Savings: 836.4 liters – 418.38 liters = 418.02 liters pr. day. 17.4175 liters(418.02/24)/hr X 6,000 r. hrs. X 2.10 USD/liter(/1.30 EUR)=168,815 EUR/year
Yearly estimated savings more than EUR 168,000
Sulzer 12RT-flex96C
SAVINGS CALCULATION AT TARGET FEED RATE
Target feed rate (g/kWh)
Savings per vessel per year (EUR)
0.8 112,640
0.7 140,800
0.6 168,000
0.5 197,120
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
HJ Lubtronic SIP - Hardware AND Est. installation + liner machining –Break even in 1.83 years– Target F/R 0.6 g/kWh
CASH FLOW
*Above calculations are based on assumed specification of hardware and engine condition and are subject to change, if any, based on final specification.
Months Expense Accumulated saving Cashflow
0 -309.850,00€ -€ -309.850,00€
1 14.080,00€ -295.770,00€
2 28.160,00€ -281.690,00€
4 56.320,00€ -253.530,00€
6 84.480,00€ -225.370,00€
8 112.640,00€ -197.210,00€
10 140.800,00€ -169.050,00€
12 168.960,00€ -140.890,00€
14 197.120,00€ -112.730,00€
16 225.280,00€ -84.570,00€
18 253.440,00€ -56.410,00€
20 281.600,00€ -28.250,00€
22 309.760,00€ -90,00€
24 337.920,00€ 28.070,00€
36 506.880,00€ 197.030,00€
48 675.840,00€ 365.990,00€
Cash flow - net cash payment
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
Sulzer 12RT-flex96C
QUOTATION
*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.
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.
INSTALLATION
*Not including cylinder machining
•Order
•Data collection
Month 1
•Production
Month 2
• Installation
Month 3
PROJECT TIMELINE
Feed Rate Optimization Program begins: 2-3 reports per year
FEED RATE OPTIMIZATION PROGRAM
Lubrication system
Service Experience Hans Jensen Lubricators
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
FEED RATE OPTIMIZATION PROGRAM
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
Scrape Down Analysis
1 2 3 4 5 6
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 895 820 1190 1320 1340 1110
Iron Mar 213 514 545 606 365 302
Iron Jun 559 976 1036 516 487 645
Si+Al Feb 99 94 116 117 118 108
Si+Al Mar 77 90 93 93 100 79
Si+Al Jun 189 225 252 162 167 193
0,0200,0400,0600,0800,0
1000,01200,01400,01600,0
pp
m
Feed rates Feb: 0,4 g/kWh Mar: 0,5 g/kWh Jun: 1,0 g/kWh
Exa
mp
le
Lubrication system
Service Experience Hans Jensen Lubricators
FEED RATE OPTIMIZATION PROGRAM
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
Port Inspection Report
Exa
mp
le
Lubrication system
Service Experience Hans Jensen Lubricators
FEED RATE OPTIMIZATION PROGRAM
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
Based on a century of experience
Report example
7RTA58T - HJ SIP
OPERATIONAL EXPERIENCES
Data Installation date: 12/4-2010 ME running hours after HJ SIP installation: 9.594 Feed rate before installation: 1,08 g/kWh Feed rate after installation: 0,66 g/kWh CLOC after installation 180 L/day
Piston rings are in good condition. Minor combustion issues, but lubrication is adequate.
1 2 3 4
5 6 7
PISTON SKIRTS GOOD CONDITION – FEW DEPOSITS
7RTA72U-B – HJ Lubtronic SIP
OPERATIONAL EXPERIENCES
Data Feedrate: 0,8 g/kWh Date: 23-05-2013
Data Feed rate: 0,7 g/kWh Date: 15-08-2013
Clear signs of overlubrication – lube oil is visible
Improvement in lubrication – less oil visible, with no signs of wear on skirt
PISTON RINGS
FINE CONDITION – MARGINALLY WET
7RTA72U-B – HJ Lubtronic SIP
OPERATIONAL EXPERIENCES
Data Feed rate: 0,7 g/kWh Date: 15-08-2013
Data Feedrate: 0,8 g/kWh Date: 23-05-2013
Poor combustion – potential overlubrication as there is wet and black oil on piston rings
Signs of overlubrication, but not alarmingly so. Rings and ring-land are nice and clean.
PISTON TOP
GOOD CONDITION
7RTA72U-B – HJ Lubtronic SIP
OPERATIONAL EXPERIENCES
Data Feed rate: 0,7 g/kWh Date: 15-08-2013
Data Feedrate: 0,8 g/kWh Date: 23-05-2013
Signs of overlubrication -white/grey deposits on top.
Adequate lubrication.
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
HJ Lubtronic SIP
CONCLUSION