4 Stroke

FUEL 2020 – Sulphur cap
Recommendations for
trouble-free genset operation from 2020
Lennart Wahl
Manager
Engineering Support, 4 stroke
Holeby
Hamburg 07.11.2018
How to comply – 2020 sulphur cap
Genset operational solutions
1) Continue HSHFO
-> Install scrubbers
2) Change Fuel
a. Ultra Low Sulphur Fuel Oil
b. Very Low Sulphur Fuel Oil
c. Distillate Fuels - DM
3) Convert to
d. Bio Fuels
LNG/Dual Fuel
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Lennart Wahl 07.11.2018
2020 fuels - Abbreviations and caracteristics
Fuel types from crude oil
ULSFO & VLSFO

• Viscosity: between DM and HFO
• Density: could be close to DM
ULSFO*: 0,1% S • Poor point: High – temperature!
Destilates – DM* Mixing • Aliphatic: Good ignition/combustion
VLSFO*: 0,5% S • Wax formation tendency

Residuals – RM* • Catfines – be prepared!
HSHFO*: 5,0% S • Incompatibility – don’t mix
• Tanks, Cleaning effect -> Clog filters
• Separator - Change of gravity disc
*Specified in ISO 821,7 ISO and CIMAC confirmed
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How to comply – the 2020 sulphur cap
1) Continue HSHFO
2) Change Fuel
d. Bio Fuels
3) Convert to
LNG/Dual Fuel
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Operating Genset on HSHFO with scrubbers
HSHFO w/scrubber vessels:
Must comply with local SECA/ECA (0.1%S)
Recommend
 Select one genset: ULSFO
 Remaining gensets: HSHFO
HSHFO - ULSFO, Change-over :

 Controlling fuel temperature/viscosity
 Selecting correct BN lube oil
Note:
Increased exhaust back pressure ->
• Increased SFOC
• Increase exhaust gas temp.
• Reduced turbocharger surge margin
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1) Continue HSHFO
2) Change Fuel
d. Bio Fuels
3) Convert to
LNG/Dual Fuel
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ULSFO contains Catfines
Automatic filter in Circulation loop is necessary
10µm abs
Required by 4S
Required by 2 stroke
Supply line
Circulation loop
 Repeated cleaning
 Synergy with Separator (1+1=3)
 Commission/overhaul (flushing)
Omit
 Generated in system (normal/damage)
Public
Service Experience - Install 10µm Autofilter
In circulation loop
Before 10 µm abs After
Filter
 Clean combustion
 No particles
 No damage to nozzles
 No sticking fuel pumps (seizure)
Public
ULSFO Genset Service Experience
6L28/32H, 0,08% S
Inspection at 2225 hrs. Cyl. No. 1. Conclusion:

 All parts in good condition
 No abnormal or extra wear
 Some lacquer and coke deposits on liner and nozzle
Reason most likely:
 Low load operation
 Lube oil additives to be adjusted to ULSFO
Public
Retrofit - Fuel filter package
• 10µm Fuel Oil Auto Back-Flush Filter

• 25µm Fuel Safety Filter
• Wet and Dry cleaning tools for Turbine
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1) Continue HFO
2) Change Fuel
d. Bio Fuels
3) Convert to
LNG/Dual Fuel
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Continuous operation on Low viscosity Distillate fuels
MDO/MGO
Pay attention to:
1) Avoid seizure of fuel oil injection pump
2) Increased leak oil amount from fuel injection pumps/valves
4) Increased wear on valve spindles
3) Select correct lubricating oil
Details to come…
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1) MDO/MGO cooler – may be necessary
• Ensure correct viscosity > 2 cSt
• Avoid heating up the service tank Retrofit: Cooler or Chiller
In hot environment
a Chiller unit may be necessary
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1) Coated plunger: Higher margin against seizure
when running on low viscosity fuels
DLC coating of plunger/barrel – latest standard

Retrofit: DLC coated plungers
Increased margin by DLC-coating:
1) Short-term operation at viscosity below 2 cSt
2) Particle related seizures
DLC Coated Uncoated
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2) Continuous operation on Low viscosity Distillate fuels
Reuse the clean drain oil
Retrofit - Drain split
Collect and re-use the clean oil
All engine types

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3) Continuous operation on Low viscosity Distillate fuels
Excessive wear on valve cones
Finding: Heavy wear on inlet valve spindle seat

Cases: Only few engines suffer from this.
Fuel: VLSFO – DM or LNG i.e. low lubricity
Retrofit: Spindles with T-400 armouring
Never been seen on engines running on HFO
New materials for inlet/exhaust valves:

• Higher heat resistance
• Require less lubrication
-> Ensure longer lifetime
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4) Selection of Lube Oil
The Challenge of changing fuels
MDO w/ high sulphur content
Sulphur
BN 20
HFO Sulphur content < 0.5 %.
23/30, 28/32 Normal operating conditions.
BN 30
16/24, 21/31, 27/38, 32/40 HFO only, sulphur < 1.5 %.
23/30 and 28/32 Under unfavourable conditions
BN 40
16/24, 21/31, 27/38, 32/40 HFO only, sulphur> 1.5 %.
In and out of SECA:

BN must satisfy requirements for fuel with high-sulphur content
<1000 hrs in SECA:

Keep BN 30/40
>1000 hrs. In SECA:

IN: Change to BN 20 for ULSFO Replenishing is sufficient
OUT: Change back to BN 30/40 for HSHFO Start replenishing 2 weeks before
Must be same manufacturer
Public
Short term operation on Destillate fuels
Engine designed for continuous HSHFO and MD operation
Occasionally, changes between HFO and MDO/MGO:

Considered normal operation, however:
viscosity, cSt
Careful change-over
Risk of seizures
At Viscosity below 2 cSt.
Fuel
Set visc. to
18 cSt Stop steam tracing
18
Fuel temperature gradient:
10-15 Max. 2°C/min.
Stop
preheater
Start cooler
10
Heavy Fuel (HFO)
Retrofit: Diesel Switch Diesel (DO)

2
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Fuel pump sealing oil for L27/38
Design feature of L27/38
Function of sealing oil
Lube oil between plunger and barrel in lower part of
Sealing oil: prevent fuel leaking into lube oil pump element as a barrier.
• Required in MDO/MGO-operation
• Not required for HFO operation
Retrofit:
- Permanent sealing oil
- Automatic switch ON/OFF by SaCoS
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L23/30H and L28/32H on DM-fuels
Risk of liner lacquering
Retrofit:
New thermostatic element
• Increased HT temperature
• Reduce risk of lacquering
Cooling water
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Service Experience, DM - Arctic Gas Oil,
L16/24. DM with 0.2% S
Remote power station working in extreme arctic climate: Arctic gasoil w/ 0.2% S
Overhauling:
 12,000 running hrs.
 30,000 running hrs.
 72,000 running hrs. (2010)
Today approx. 100,000 running hrs. (standby)
Two new (extra) engines in 2006
Planned TBO of 42,000 running hrs. (2018)
Public
Lube oil consumption L23/30
Service experience & field test results
HSHFO Retrofit: New piston ring package
 New bush for rocker arm
3rd piston ring
 New oil scraper ring.
Barrel shape
-> Consumption within range
old
VLSFO-DM
Problem:
VLSFO-DM or
HSHFO and <-> VLSFO-DM Conical shape Cylinder liner lacquering
Cylinder liner lacquering New
-> Consumption very high
Countermeasure:
• New 3rd piston ring
Results
Engines operated on VLSFO-DM or
switching between HSHFO and VLSFO-DM
New 3rd ring ->
Lube oil consumption 4-8 litres pr. Day.
Public
1) Continue HFO
2) Change Fuel
d. Bio Fuels
3) Convert to
LNG/Dual Fuel
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Operating Gensets on bio fuels
Non-fossil fuels, from organic materials - plant materials and animal waste
Fuel type/properties determine requirements for retrofitting
Some caracteristics:
• High cost
• Extremely low Sulphur content
• May have high TAN
• Concerns about storage and oxidation stability
• High volume production not established
Retrofit:
- Coated fuel pump elements (high TAN)
- Heat tracing: Drain pipes, fuel pipes, filters
Please refer to “Explanatory notes for biofuel” - 3700063-9.0

For specification on bio fuel please refer to our document D010.000.023-02-0001
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1) Continue HFO
2) Change Fuel
d. Bio Fuels
3) Convert to
LNG/Dual Fuel
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Dual fuel conversion
L23/30H and L28/32H
Retrofit to dual fuel

- LNG as main fuel
- MGO as pilot injection fuel
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Retrofits - overview
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Disclaimer
All data provided in this document is non-binding.

This data serves informational purposes only and is especially not guaranteed in any way.
Depending on the subsequent specific individual projects, the relevant data may be subject to changes and
will be assessed and determined individually for each project. This will depend on the particular characteristics
of each individual project, especially specific site and operational conditions.
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Thank you
very much
Extra
Water Leaking from exhaust valve seat
Public
Leaking Cyl. Head, Exh. valve
Investigated cylinder head
Cooling water inlet
Excessive amounts of Rust/lime scale filling-up cooling space Heavy layer of rust/lime scale
rust/lime scale Blocking cooling water flow preventing cooling
Blocking cooling water inlet Less efficient fuel spray
due to reduced viscosity of fuel
Public
Cooling water treatment - Example
Concentration differ MAN and Maker
MAN recommended
Maker recommended
Initial dosage for an untreated

system is 9 litres of Rocor NB
Liquid/1000 litres of untreated
distilled water.
This will bring the treatment up to the
minimum level of 1000 ppm nitrite.
Normal nitrite limits: 1000-2400
ppm nitrite (NO2)
Public
Conclusions - Example
Leaking Exhaus valve seats – Specific vessel
Rapid corrosive attack due to: Severe problems after 2300 hrs.
1. Low inhibitor levels
2. High bacteria levels
3. High cloride level
Causing
Corrosion scale build-up
-> preventing cooling water flow
-> Overheating, exhaust valve seat
-> Water leakages
Root Cause:
• Too low level of inhibitor aggrevated by bacteria
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Corrosion vs inhibitor concentration
The extreme risk at low inhibitor levels
Public
Nitite-free/organic based inhibitor
Non-toxic
Havoline® XLI is an environmentally sensitive coolant and

corrosion inhibitor concentrate based on extended-life
organic acid Carboxylate Technology.
Public
Disclaimer
All data provided in this document is non-binding.

This data serves informational purposes only and is especially not guaranteed in any way.
Depending on the subsequent specific individual projects, the relevant data may be subject to changes and
will be assessed and determined individually for each project. This will depend on the particular characteristics
of each individual project, especially specific site and operational conditions.
Public 37

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FUEL 2020 – Sulphur cap

ULSFO & VLSFO

ULSFO*: 0,1% S • Poor point: High – temperature!

Destilates – DM* Mixing • Aliphatic: Good ignition/combustion

VLSFO*: 0,5% S • Wax formation tendency

HSHFO - ULSFO, Change-over :

Before 10 µm abs After

Inspection at 2225 hrs. Cyl. No. 1. Conclusion:

• 10µm Fuel Oil Auto Back-Flush Filter

Pay attention to:

1) Avoid seizure of fuel oil injection pump

2) Increased leak oil amount from fuel injection pumps/valves

4) Increased wear on valve spindles

3) Select correct lubricating oil

DLC coating of plunger/barrel – latest standard

DLC Coated Uncoated

Retrofit - Drain split

Collect and re-use the clean oil

All engine types

Finding: Heavy wear on inlet valve spindle seat

New materials for inlet/exhaust valves:

MDO w/ high sulphur content

In and out of SECA:

<1000 hrs in SECA:

>1000 hrs. In SECA:

Occasionally, changes between HFO and MDO/MGO:

Heavy Fuel (HFO)

Retrofit: Diesel Switch Diesel (DO)

Fuel type/properties determine requirements for retrofitting

Please refer to “Explanatory notes for biofuel” - 3700063-9.0

Retrofit to dual fuel

All data provided in this document is non-binding.

Cooling water inlet

Initial dosage for an untreated

Havoline® XLI is an environmentally sensitive coolant and

All data provided in this document is non-binding.

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