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2012
Fig. 1 The Maersk Line's container vessel EDITH MRSK with a 14-cylinder Wrtsil RT-flex96C main engine will be fitted
with Blending on Board in 2012.
Blending on Board (BOB) is a new concept Traditional cylinder and engine lubrication achieved by the special detergency and
developed by Maersk Fluid Technology Inc Two-stroke cross-head diesel engines dispersancy properties of the additives
with whom Wrtsil has a co-operation typically use at least two different oils O To prevent cold corrosion by
agreement for the joint marketing and besides the fuel oil: the general system neutralizing the acidic species created
sales of the system. BOB optimises the oil, which serves as the lubricating and during engine operation. The main acid
overall lubrication performance of large cooling oil for engine components; the to be neutralized is the sulphuric acid
bore diesel engines. It also enhances special cylinder lubricating oil, which produced from the sulphur content
operational flexibility and independency. lubricates the piston ring/cylinder liner of the fuel burnt in the engine.
contact; and the servo oil, which in Wrtsil
two-stroke engines is the system oil. Cylinder lubricating oil is injected into
The cylinder lubricating oil is the cylinder via the cylinder lubrication
specially formulated with additives system (on Wrtsil two-stroke engines,
to fulfil three main purposes: e.g. the CLU-3 or the Pulse Lubrication
O To create a sufficient oil film between System). The cylinder lubricating oil and
the running surfaces of the cylinder liner system oil are separated in two-stroke
and the piston rings to minimize friction cross-head engines by stuffing boxes.
and wear of the components The system oil usually remains for a long
O To clean the piston, piston rings, and time in the engine as it is consumed in only
cylinder liner from deposits, which is relatively small quantities. During
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WRTSIL TECHNICAL JOURNAL 01.2012
The cylinder lubricating oil is blended The system is compact enough to be The product is based on a blender and
from used system oil and additives for transported through a normal door. Some an analyzer, which are installed onboard
achieving the required BN level and oil modifications to the existing piping and the vessel.
properties. tank allocation are necessary, but no new Some modifications to the existing piping
tank installations are required. The Blending and tank allocation will be necessary.
on Board system is ABS and Lloyds
Register approved.
used oil volume), and is then blended The SEA-Mate Blender is a compact,
with a specially formulated cylinder oil robust, reliable and easy-to-use piece of
additive. The result is customized cylinder equipment, designed to fit an engine rooms
oil for each vessels specific operating environment. It is connected to the Used
conditions, thus reducing a vessels lube System Oil Tank for BOB and the Additives
oil consumption by 10%-50%, depending Tank on one side, and the Blended Cylinder
on the currently used feed rate. With the Oil Tank and/or Day Tank on the other side.
now frequent transfer of system oil to the
blender, the vessel is able to replenish the The operator onboard enters the following
engine sump with fresh oil, without any values on the screen of the blender control
waste oil disposal, which results in a cleaner panel:
engine and better engine performance. O The used system oils BN level this can
be determined beforehand from
Installing the Blending on Board system the Analyzer
The solution has been designed in a O The additives BN level this needs to be
modular way in order to allow easy entered just once at the beginning, unless
installation. The BOB system consists of a different additive product is purchased
a blender with a blender control panel, and at a later stage
an XRF analyzer (either with or without O The target BN level for the new batch of
the ability to detect cat fines). blended cylinder oil the value can be
The product names are: determined from Blending on Board
O SEA-Mate Blender B3000 instructions (and in the future will be
O SEA-Mate Analyzer M2000 an integrated function in the blender
(without cat fines detection) control panel)
O SEA-Mate Analyzer M3000 O The amount in tonnes for the new batch
(with cat fines detection) of blended cylinder oil. Fig. 3 SEA-Mate Blender B3000.
Fig. 4 Target BN levels for the blended cylinder oil for different fuel S%.
120
110
100
90
80
Blended oil BN
70
60
50
40
30
20
10
0
0.5 1 1.5 2 2.5 3 3.5 4 4.5
HFO S% content
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After pushing the Start button, the blender reporting, as well as data export.
completes the required blending on its The SEA-Mate Analyzer is available
own. Optionally, the operator can also in two different versions. The SEA-Mate
set the blender operation on automatic, M2000 is designed for analyzing lubricants
which will repeat the blending process with and fuel sulphur only, while the SEA-Mate
the set values, once the blended cylinder M3000 is intended for analyzing both
oil tank reaches a set minimum level. lubricants and fuels, and it includes the
The SEA-Mate Blender B3000 is equipped detection and measurement of cat fines
with all class-required features for safe in the fuel. Besides BN levels of lubricants,
maritime operation. various elements can be detected and
The SEA-Mate Analyzer is an integrated accurately measured in lubricants and fuels.
part of the Blending on Board installation. The XRF technology enables the detection
It is an advanced XRF technology based and measurement of total iron (Fe), which
analyzer that provides state-of-the-art makes the SEA-Mate Analyzer a unique
onboard or on site analysis capability for tool, most especially in monitoring the
lubricants and fuels. It also provides condition of the cylinder and piston
the operator with a whole new level of components, as it enables the detection
awareness and knowledge regarding the of both abrasive and corrosive wear.
importance of lubrication oil, engine The analyzers were tested in long field
condition and monitoring. It is designed in tests, and measuring results from the SEA-
a robust way, gives the user clear on-screen Mate Analyzer were compared with results
guidance and instructions, and provides from professional land-based laboratories
analysis results within only six minutes. run from the same samples. The latter
The analyzer is supplied together with comparison showed a very good correlation
2
a bar-code reader and all required sample (R >0.95) between the laboratory results
bottles and bar-code labels for sampling and the SEA-Mate results.
locations and bottles. This enables the easy Installation of the Blending on Board
handling of sampling and provides unique system is relatively simple and can be done
Fig. 5 SEA-Mate Analyzer M3000. management for analysis data. The software without interrupting the vessel's commercial
offers various possibilities for trending, operations. After installation of the SEA-Mate
#
!
"
$%
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WRTSIL TECHNICAL JOURNAL 01.2012
Blender and making the necessary piping Field test results two-stroke engines are more prone to
and tank adaptations, the total system is Wrtsil followed the strict and demanding corrosion attacking the cylinder liners and
commissioned by a senior engineer and product market introduction process piston rings.
the crew is trained to use and operate determined for oil applications. This To reduce the corrosion, Wrtsil and
the blender and analyzer. procedure was started by an independent other engine designers recommend
LOQUS laboratory analysis of the blended increasing the cylinder lubrication oil feed
Co-operation with Maersk cylinder oils, and a comparison of the rate in order to increase the neutralisation
Fluid Technology findings with the properties of commercially effect. Once the Blending on Board
The Blending on Board concept and the available cylinder oil products. The equipment is in use on a vessel, the
SEA-Mate Blender and Analyzer products laboratory analysis was followed by reduction in corrosion can be achieved by
were invented, designed and patented by extensive field testing throughout 2011. adjusting the BN of the lubricant, and not by
Maersk Fluid Technology (MFT), a subsidiary Various combinations of blended oils at increasing the cylinder oil feed rate.
of the A.P. Moeller-Maersk group. Both different BN levels, with different operational In one of the field tests, it was observed
the concept and the system products have, loads and different fuel sulphur contents, that with the correct BN adjustment, and
within the past four years, been installed in were tested and the condition of the piston the blended oil having a high BN level of 105,
25 Maersk Line container vessels, of which running components subsequently checked. the maximum corrosive wear was decreased
eleven have Wrtsil two-stroke main engines. All tests were concluded successfully with by 48%.
After analyzing the technical feasibility very positive impact on the engine operation In addition to these effects, a fast recovery
of the Blending on Board concept, and its and cylinder lubrication costs. Different of the engine's cleanliness was observed
potential as a new flexible engine lubrication cylinder oil additives from different oil after the introduction of Blending on Board
management approach for the market, suppliers and many different operational on a 9000 TEU container vessel with a
Wrtsil and MFT entered into a co-operation patterns were tested. These field test 12-cylinder Wrtsil RT-flex96C main engine.
agreement in the beginning of 2011 for activities have resulted in numerous The majority of the used system oil was
the joint marketing and sales of the system. "Letters of No Objections" and the full replenished with fresh system oil, and the
An extensive field testing and approval endorsement of the Blending on Board used oil was utilized for the blending of
process, for both the system capabilities and concept and operation by Wrtsil. the required cylinder oil. Thanks to the
the performance of various BN levels of When operated in harsh conditions (high Blending on Board process, the system oil
blended cylinder oils with different system sulphur content of the heavy fuel oil, low is regularly refreshed, thus keeping the system
oils and additives, was also initiated. engine load leading to lower temperatures, oil in its optimal condition and the engine
high humidity in the scavenge air, etc.), components clean.
Furthermore, as regards engine
cleanliness, it was also observed that the
lifetime of the vital engine components, such
Table 1 Detection capabilities and measurement accuracy of the SEA-Mate Analyzers.
as bearings, hydraulic components in
the RT-flex system, piston crowns, etc, can
be prolonged as a result of running on fresh
system oil.
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Fig. 7 The layout and flow diagram of the Blending on Board system.
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WRTSIL TECHNICAL JOURNAL 01.2012
Fig. 89 Condition without BOB. Fig. 1011 Condition with BOB installed.
Fig. 12 During a field test on a 12-cylinder Wrtsil RTA96C engine at different loads, the correct level of BN in the blended cylinder oil resulted
in substantial reductions of corrosive wear.
Total Iron content of piston underside drain oil during operation with BOB cylinder lubricant.
300
BOB 79 BN BOB 105 BN
250
48%
200
Fe (ppm)
150
17%
100
50
0
0 15 30 45 60 75
Load % CMCR
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For the below case calculation, the following parameters were used:
Engine type 7-cylinder Wrtsil RT-flex96C
Yearly running hours 6000
Cylinder lubrication system (CLU3 or CLU4) CLU3
Average engine load 50%
Cost standard system oil (USD/t) 1550
Cost standard cylinder oil (USD/t) 2000
Cost additives (BP, XOM, PC) (USD/t) 3500
Cost fuel price (USD/t) 600
Estimated savings and payback times per year with Blending on Board:
Approx. savings Cumul. Savings Payback times
Areas of cost savings
in USD/year in USD/year in years
Annual savings from cost difference between standard cylinder oil and blended
110,000
cylinder oil and from reduced feed rate (0.1 g/kWh assumed)
130,000 < 2.5
Annual savings from reduced system oil losses through separator discharging,
20,000
due to extended discharge intervals
Annual savings from reduced maintenance and spare parts costs due to better
50,000 180,000 < 2.0
component condition and TBOs
Annual fuel savings of 0.5% due to impact of reduced friction and optimal
60,000 240,000 < 1.5
viscosity coming from frequent replenishment of system oil and cleaner engine.
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