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