World Bunkering > News > Winter 2010 > Equipment & services

LS pump wear causes increasing concern

Allweiler, a provider of marine pumps to the shipping industry, has warned that increasing use of LS fuels, and frequent swapping between low and high sulphur, is leading to rapid deterioration of fuel service pumps. When BW Gas overhauled a low-performing fuel service pump, it discovered high wear on pump elements. BW Gas concludes that, while the use of 0.1% sulphur marine gas oil was a contributing factor to the increased wear rate on the pump, it was clear that other factors also played a significant role.

“Today we have a lot more knowledge about the effects of low-sulphur content diesel fuels,” says Christian Martin, Business Development & Marketing, Allweiler. “Some vessels, depending on areas of operation, are more affected than others,” says Martin. The majority of pump problems occur on vessels in global operation which have to switch fuels as they enter ECA zones. “When two different fuels are mixed there is a risk of incompatibility, which may cause clogging of fuel filters and separator, sticking of fuel injection pumps and considerable pump deterioration,” he says.

Allweiler confirms that several major shipowners operating in the deep-sea trade are facing major overhauls or full pump replacements. The main concern is low viscosity levels when operating with lowsulphur diesel fuels.

Martin explains: “When switching from HFO to diesel, oil temperatures must drop from 150 degrees to 40 degrees. This process is extremely difficult to manage, due to the resulting low viscosity of diesel caused by too high temperatures. Or the very high viscosity HFO levels caused by too low temperatures.”

Extremely low-sulphur content and consequent low viscosity levels have a strong impact on fuel injection and pump/valve lubrication. Pumps must be capable of handling low viscosity fuels while retaining the required pressures and capacities.

Allweiler is experiencing an increased demand by shipowners for technical evaluations and modification recommendations of existing pumps. “Compared to the past, today’s fuel oil pumps encounter new operational conditions. Shipowners are in doubt about the effects of low-sulphur content diesel fuels and the limits that pumps can handle, especially when exposed to mixed fuels,” says Martin. “Optimal pump performance depends on the type of materials used to construct the pump, which must be appropriate for the liquid’s chemical and physical properties, operational conditions, such as pressure, speed, temperature, and the areas of operation.”

Lubmarine launches new LS luboil

Marine lubricants supplier, TOTAL Lubmarine, launched what it claims is a revolutionary cylinder oil at SMM 2010. Talusia Universal is designed to solve engine wear problems encountered by owners and operators in meeting regulatory and environmental requirements relating to sulphur limits.

“Lubricants have not always been top of the priority list for shipowners. But this is changing. In the current economic climate, shipoperators simply cannot afford to ignore any potential cost savings that can easily be made,” said Patrick Havil, global marketing manager of Lubmarine. “In the current legislative climate, shipoperators are forced to face issues arising from the need to operate within Emission Control Areas (ECAs). They must also, above all else, observe the highest standards of safety in order to protect both their workforce and the environment.

“When the difficulties of operating in ECAs are raised, we often hear about the challenges involved in switching fuels,” Havil continues. “What is often not mentioned is the fact that shipoperators also face similar challenges in terms of lubricant switching. Talusia Universal has been the only lubricant on the market until now which can be used with fuel of all sulphur contents, meaning that the need to switch lubricants when moving in and out of an ECA is completely removed.”

Lubmarine undertook a specific test with a MAN engine on a containership running continuously on a fuel containing less than 1% sulphur for 4,200 hours, and MAN certified that the results were good. It is believed that Talusia Universal is the only lubricant to have achieved a successful field test over more than 4,000 hours with an HFO containing less than 1% sulphur. This was achieved with a feed rate of 0.60 g/kWh, the lowest figure recommended by MAN. Havil also outlined Lubmarine’s progress with the next incarnation of the new generation of lubricants, including a universal oil for the 2015 market that will give optimum assured performance from the highest sulphur content HFOs right down to less than 0.1% sulphur content fuels, and a range of biodegradable lubricants.

Martek launches exhaust monitoring system

Martek Marine has recently launched a monitoring system that measures the density of the smoke being emitted by a vessel to prove compliance with new stringent regional rules against ships exhausting black smoke within sight of shore. The system, known as ‘Vigilant’, uses a transmitter and a receiver on either side of the ship’s funnel to measure the density of the smoke and grade the results in terms of the Ringelmann Scale. It is suitable for use on either auxiliary or main diesel engines, and can be connected to a PC, where full data logging and alarm summaries can be recorded for historical use.

Wärtsilä introduces ORC technology

Wärtsilä has signed an exclusive agreement with Italy-based company Turboden to jointly develop, market, and distribute the Wärtsilä Marine Engine Combined Cycle (ECC) product. Marine ECC uses Organic Rankine Cycle (ORC) technology to improve energy efficiency and reduce fuel consumption, thereby cutting both operating costs and exhaust emissions. The joint development work will initially focus on applying the ORC technology for ship applications, and the Wärtsilä Marine ECC product is expected to enter the market during 2011.

The Wärtsilä Marine ECC provides a means of obtaining an efficient and reliable small-scale combined cycle system from the otherwise wasted energy recovered from downstream exhaust gas, and/or from the high-temperature cooling water of reciprocating engines. This could provide added power in the range of 8% to 12% to the prime mover. Typical sizes range from hundreds to several thousand kWe.

At the same time, and as a direct result, exhaust gas emissions are lowered and this too aids the operator in meeting increasingly stringent environmental regulations. With the Marine ECC in operation, fuel oil consumption is significantly lowered, which in turn provides the operator with reduced operating expenses. “Because of high fuel prices and the need to reduce emissions, improving energy efficiency is today a matter of great importance to our customers. The Marine ECC will benefit both the customer and the environment, and is, therefore, completely in line with Wärtsilä’s strategy,” says Juha Kytölä, vice president, Product Centre Ecotech, Wärtsilä.

The Rankine Cycle is a thermodynamic cycle that converts heat into work energy. Water is the most commonly used working fluid in Rankine Cycle systems, which generate the majority of the electricity used throughout the world. The ORC, on the other hand, can operate using various organic fluids to utilise the waste heat from exhaust gas, and from lower grade heat sources such as high-temperature cooling water.

While the ORC is already a well-established form of energy production with an increasing application base, it is new to the marine market. The ORC technology provides many advantages, including high thermodynamic cycle efficiency, the ability to operate at lower heat source temperatures, simple start-up procedures, automatic and continuous operation without operator intervention, simple maintenance procedures, and long lifecycles.

“Following the very positive results that Turboden is now achieving with heat recovery systems for stationary internal combustion engines, we are now excited to be working with Wärtsilä to develop an ORC solution specifically applicable to the marine market,” says Paolo Bertuzzi, general manager, Finance & Commercial Area, Turboden.