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Pon Power Seminar Gen Set Rental Day Sept10 Ip Pon Power Seminar Gen Set Rental Day Sept10 Ip Presentation Transcript

  • CLEAN OIL PON Power, Gen-Set seminar, Fuel and Engine oil BRIGHT IDEAS www.ccjensen.nl Gen-Set seminar, best practice for fuel & engine oil management. C.C.JENSEN Benelux B.V., Ivan Partono, Sept 2010 Page 1
  • CLEAN OIL PON Power, Gen-Set seminar, Fuel and Engine oil BRIGHT IDEAS www.ccjensen.nl Content: 1. Introduction C.C.Jensen 2. Diesel fuel EN590 (low sulphur): • Specifications and SECA (Sulphur Emission Control Area). • Problems and trouble shooting → high water content, bacterial growth, impurities in fuel tanks. • CJC Filter Separator, purification of fuel (removal of water and particles). • Best practice, preventative maintenance. • Related issues; Biodiesel(EN14214) 3. Engine oil: • Manufacturer specifications, EGR (Exhaust Gas Recirculation), oil additives. • Problems and trouble shooting → short drain intervals, bore polishing, sludge formation. • CJC Fine Filter, 3µ particles & soot removal, Acid neutralisation, TBN stabilisation, Fuel dilution. • Best practice, drain interval extensions →savings and environmental impact. • Related issues, engines on bio fuel → MAN diesel 8.5MW (Oostende), ABC diesel 2.5MW (Kesteren). 4. Application studies and related projects: • KLM Equipment Services, Schiphol Airport Amsterdam, GPU (Ground Power Unit), Gen-Set fuel and engine oil. • APM Terminal, Port Said Egypt, RTG (Rubber Tired Gantry), Gen-Set Engine oil. • CIV Texel fuel station. 5. Benefits and ROI (Return Of Investment) 6. Presentation of demo units PTU and HDU, seeing is believing. C.C.JENSEN Benelux B.V., Ivan Partono, Sept 2010 Page 2
  • CLEAN OIL PON Power, Gen-Set seminar, Fuel and Engine oil BRIGHT IDEAS www.ccjensen.nl 1. Briefly about C.C.JENSEN A/S • A limited company, family owned – established in 1953 • >200 employees in Denmark • 10 subsidiaries + 2 sales office Filter Division abroad, with > 80 employees • Production of: • Ship windows → 15% • Casting of ship propeller → 15% • Oil & Fuel Filtration → 70% • Export: 65% Window & Casting Division C.C.JENSEN Benelux B.V., Ivan Partono, Sept 2010 Page 3
  • CLEAN OIL PON Power, Gen-Set seminar, Fuel and Engine oil BRIGHT IDEAS www.ccjensen.nl The Filter Premises Løvholmen 18 Løvholmen 9 & 13 The new Factory in Hesselager C.C.JENSEN Benelux B.V., Ivan Partono, Sept 2010 Page 4
  • CLEAN OIL PON Power, Gen-Set seminar, Fuel and Engine oil BRIGHT IDEAS www.ccjensen.nl The Filter Production Off-line Filtration Systems From OEM Products to Special Solutions C.C.JENSEN Benelux B.V., Ivan Partono, Sept 2010 Page 5
  • CLEAN OIL PON Power, Gen-Set seminar, Fuel and Engine oil BRIGHT IDEAS www.ccjensen.nl Production per Year Filter Inserts > 120,000 Filter Units > 11,000 C.C.JENSEN Benelux B.V., Ivan Partono, Sept 2010 Page 6
  • CLEAN OIL PON Power, Gen-Set seminar, Fuel and Engine oil BRIGHT IDEAS www.ccjensen.nl WORLDWIDE NETWORK Europe Active on 5 continents - in more than 40 countries North America South America Africa & Middle East Asia & Australia C.C.JENSEN Benelux B.V.,Presentations, Sept 2010 A/S, General Ivan Partono, C.C.JENSEN Worldwide Network, No. 1-14, - August 2009 Page 7
  • CLEAN OIL PON Power, Gen-Set seminar, Fuel and Engine oil BRIGHT IDEAS www.ccjensen.nl 2. Diesel Fuel EN590 describes the physical properties that all automotive diesel fuel must meet if it is to be sold in the European Union, Iceland, Norway and Switzerland. Allows the blending of up to 7% fatty acid methyl ester with 'conventional' diesel - a 93/7 mix. Source: Wikipedia C.C.JENSEN Benelux B.V., Ivan Partono, Sept 2010 Page 8
  • CLEAN OIL PON Power, Gen-Set seminar, Fuel and Engine oil BRIGHT IDEAS www.ccjensen.nl EN590 itself is a high quality low sulphur fuel which, in the “modern” engines will perform well, will give a good clean burn, has a slightly lower density resulting in a slightly higher fuel consumption which is more or less compensated by it’s somewhat higher heating value and its lubricity is due to additives acceptable. It’s even the case that the so-called “modern” engines are required to use fuel with less than 50 ppm anyhow. EN590 sulphur free fuel has the following advantages: a) it leads to a reduction of SO2 and particulate emissions. b) it is necessary for future engine emission control technologies such as EGR (Exhaust Gas Recirculation) and exhaust after treatment systems (it is also specified by the engine manufacturers for modern new engines). c) it would allow for cost effective retrofit after treatment systems such as DPF (Diesel Particulate Filters) and selective catalytic reduction of NOx. Source: IVR report on the impact on implementation of low sulphur fuel in seagoing vessel per 1-1-2010 and inland navigation per 01-01-2011. C.C.JENSEN Benelux B.V., Ivan Partono, Sept 2010 Page 9
  • CLEAN OIL PON Power, Gen-Set seminar, Fuel and Engine oil BRIGHT IDEAS www.ccjensen.nl Sulphur Emission Control Area C.C.JENSEN Benelux B.V., Ivan Partono, Sept 2010 Page 10
  • CLEAN OIL PON Power, Gen-Set seminar, Fuel and Engine oil BRIGHT IDEAS www.ccjensen.nl Point of interest: Water, Total Contamination and FAME (bio fuel). C.C.JENSEN Benelux B.V., Ivan Partono, Sept 2010 Page 11
  • CLEAN OIL PON Power, Gen-Set seminar, Fuel and Engine oil BRIGHT IDEAS www.ccjensen.nl Water Problems • Corrosion: There is a significant problem with water in fuel oil. Water produces abrasive rust which wears on surfaces, block clearances and break off to damage moving parts. • Cavitations in fuel pumps: Water droplets collapse under the pressure in the pump, producing high forces which “eats away” the pump wheels • Wear on injectors: the high velocity through injectors creates “blasting” with water droplets and the high pressure make water implosions (cavitations) resulting in high wear rates • Microbial Growth: Negative consequences include rancid foul odours, human health problems, biomass slimes, foaming and clogging of fuel filters and small passages C.C.JENSEN Benelux B.V., Ivan Partono, Sept 2010 Page 12
  • CLEAN OIL PON Power, Gen-Set seminar, Fuel and Engine oil BRIGHT IDEAS www.ccjensen.nl Water Creates Wear and Corrosion Fuel pump worn out by cavitation Wear and corrosion of injector C.C.JENSEN Benelux B.V., Ivan Partono, Sept 2010 Page 13
  • CLEAN OIL PON Power, Gen-Set seminar, Fuel and Engine oil BRIGHT IDEAS www.ccjensen.nl Water Creates Bacteria Growth Water contamination can result in bacteria growth Bacteria growth in oil tank Diesel with water and bacteria C.C.JENSEN Benelux B.V., Ivan Partono, Sept 2010 Page 14
  • CLEAN OIL PON Power, Gen-Set seminar, Fuel and Engine oil BRIGHT IDEAS www.ccjensen.nl Examples of microbial contamination (diesel bug) Fuel in-line filter blocked by organic contamination. Fuel tank, traces of micro organism colonies. There are known to be over 20 species of fuel bugs that can contaminate your fuel storage tank. The physical effects of microbiological contamination (diesel bug) are the formation of sludge's, bio-films (slimes) and surface or interfacial scum's. These occur in the fuel tank and also manifest themselves as material which block filters. A single cell weighing one millionth of a gram can grow into a bio-mass of slimy algae mats weighing 10 kilograms bio- within twenty four hours. Source: penninepump.co.uk C.C.JENSEN Benelux B.V., Ivan Partono, Sept 2010 Page 15
  • CLEAN OIL PON Power, Gen-Set seminar, Fuel and Engine oil BRIGHT IDEAS www.ccjensen.nl Gen-Set fuel filter clogged with organic contaminations. C.C.JENSEN Benelux B.V., Ivan Partono, Sept 2010 Page 16
  • CLEAN OIL PON Power, Gen-Set seminar, Fuel and Engine oil BRIGHT IDEAS www.ccjensen.nl Water Removal Methods • Centrifugal Separation • Cyclone Separation • Absorption • Distillation • Vacuum Distillation • Coalescer Separation • Desorption C.C.JENSEN Benelux B.V., Ivan Partono, Sept 2010 Page 17
  • CLEAN OIL PON Power, Gen-Set seminar, Fuel and Engine oil BRIGHT IDEAS www.ccjensen.nl Water Removal – Separation Centrifuge Coalescer Separation C.C.JENSEN Benelux B.V., Ivan Partono, Sept 2010 Page 18
  • CLEAN OIL PON Power, Gen-Set seminar, Fuel and Engine oil BRIGHT IDEAS www.ccjensen.nl CJC Filter Separator Guaranteed 3 micron particles removal Below 100ppm water content Low maintenance [KISS approach] Easy handling and installation Proven technology Extensive product range Solid build and long technical working life World wide supply and service Sustainable solution C.C.JENSEN Benelux B.V., Ivan Partono, Sept 2010 Page 19
  • CLEAN OIL PON Power, Gen-Set seminar, Fuel and Engine oil BRIGHT IDEAS www.ccjensen.nl Best Practice • Pre-conditioning of bulk/storage tanks, purification of fuel before usage. • Tank breathers, avoid ingress of moisture. • On board Gen-Set fuel tank purification, removal of water (condensation) and contaminations. • Fuel tank design enhancing water and contaminations to settle to designated place, the lowest part can be accessed with cleaning equipment, precaution of ‘dead stock’ in the tank. • Environmental friendly, minimize usage of hazardous chemicals (diesel bug killers) and waist disposal. C.C.JENSEN Benelux B.V., Ivan Partono, Sept 2010 Page 20
  • CLEAN OIL PON Power, Gen-Set seminar, Fuel and Engine oil BRIGHT IDEAS www.ccjensen.nl 3. Engine manufacturer specifications Diesel fuel according DIN51601 or EN590, few other specifications: • Max water content 0.1% • Max fuel temperature below flash point • Max viscosity to injectors 20cSt • Fuel filter (duplex) 20micron absolute Engine oil prescriptions: • API grade CJ-4 (and ECF-3) Note: Introduced in 2006 for high-speed four-stroke engines. Designed to meet 2007 on- highway exhaust emission standards. CJ-4 oils are compounded for use in all applications with diesel fuels ranging in sulphur content up to 500ppm (0.05% by weight) API - American Petroleum Institute (http://www.api.org/) • SAE viscosity grade, mono- or multigrade e.g. 15W40 SAE - Society of Automotive Engineers (http://www.sae.org) • Oil sampling intervals of 250 running hours C.C.JENSEN Benelux B.V., Ivan Partono, Sept 2010 Page 21
  • CLEAN OIL PON Power, Gen-Set seminar, Fuel and Engine oil BRIGHT IDEAS www.ccjensen.nl Oil Additives Anti-Oxidant or Oxidation Inhibitors e.g. zinc dithiophosphates. Anti-Foam e.g. methyl silicone polymer. Detergents and Dispersants → polar molecules that envelope sludge and soot particles e.g. calcium and barium sulfonates. Rust /Corrosion inhibitors → polar molecules that are chemically attracted to steel or iron surfaces, forms a barrier film to repel water e.g. organic acids, esters and amines. Anti-Wear (Extreme Pressure) → offers enhanced lubricity at the boundary contact between surfaces e.g. Zinc Dialkyl Dithiophosphate (AW), Sulphur-phosphorous (EP). Pour Point Depressants → allow oil and lubricants to flow at very low (wintertime) temperatures. Viscosity Index Improvers → reduce the rate of viscosity change as oil temperatures vary during service. Reserve Alkalinity → Base Number, alkalinity agents neutralizes acids. Source: Noria, Oil Analysis Basics. C.C.JENSEN Benelux B.V., Ivan Partono, Sept 2010 Page 22
  • CLEAN OIL PON Power, Gen-Set seminar, Fuel and Engine oil BRIGHT IDEAS www.ccjensen.nl Typical issues high speed diesel engines related to contaminations: • Bore polishing • Compression ratio, wear on valves and piston rings • Injectors failures • Incomplete combustion → exhaust gas emission • Fuel pump life time • Sludge formation in the oil sump • Lube oil pump breakdown • High engine oil consumption • Short engine oil drain interval, caused by: TBN (Total Base Number) decrease, Fuel dilution, Soot content, Viscosity increase, Oil change procedure, Oil degradation. C.C.JENSEN Benelux B.V., Ivan Partono, Sept 2010 Page 23
  • CLEAN OIL PON Power, Gen-Set seminar, Fuel and Engine oil BRIGHT IDEAS www.ccjensen.nl CJC Fine Filter type HDU, before and after filter. C.C.JENSEN Benelux B.V., Ivan Partono, Sept 2010 Page 24
  • CLEAN OIL PON Power, Gen-Set seminar, Fuel and Engine oil BRIGHT IDEAS www.ccjensen.nl CJC Filter Element Depth Filtration Cut-down used CJC filter insert type A 27/27 C.C.JENSEN Benelux B.V., Ivan Partono, Sept 2010 Page 25
  • CLEAN OIL PON Power, Gen-Set seminar, Fuel and Engine oil BRIGHT IDEAS www.ccjensen.nl Gen-Set, ABC engine (2500kW) on Waist Vegetable Oil → Bio CHP application C.C.JENSEN Benelux B.V., Ivan Partono, Sept 2010 Page 26
  • CLEAN OIL PON Power, Gen-Set seminar, Fuel and Engine oil BRIGHT IDEAS www.ccjensen.nl MAN 8.5MW Gen-Set on Bio-fuel, recycled Waist Vegetable Oil. C.C.JENSEN Benelux B.V., Ivan Partono, Sept 2010 Page 27
  • CLEAN OIL PON Power, Gen-Set seminar, Fuel and Engine oil BRIGHT IDEAS www.ccjensen.nl Best Practice • Correct oil drain procedure • Life time extension engine parts • Cleaner combustion → less emission • Best choice (engine) oil type • New oil deliveries and storage • On board automatic oil level control system • Additional by-pass or off-line depth filtration • Periodical oil sampling and trend analysis • Less used oil disposal • Predictive and proactive maintenance C.C.JENSEN Benelux B.V., Ivan Partono, Sept 2010 Page 28
  • CLEAN OIL PON Power, Gen-Set seminar, Fuel and Engine oil BRIGHT IDEAS www.ccjensen.nl 4. Related projects Ground Power Unit, 140kVA → “ Power by the Hour “ C.C.JENSEN Benelux B.V., Ivan Partono, Sept 2010 Page 29
  • CLEAN OIL PON Power, Gen-Set seminar, Fuel and Engine oil BRIGHT IDEAS www.ccjensen.nl Retro-fit equipments: • Automatic oil level control system (make: Groenveld) • Fuel Filter Separator type PTU15/12(BLA) • Engine oil fine filter(3µ) type HDU15/25(A) C.C.JENSEN Benelux B.V., Ivan Partono, Sept 2010 Page 30
  • CLEAN OIL PON Power, Gen-Set seminar, Fuel and Engine oil BRIGHT IDEAS www.ccjensen.nl APM Terminal Port Said, Egypt. RTG (Rubber Tired Gantry) Gen-Set, Cummins engine KTA19-G4. Achieved result: engine oil drain interval 2500 hours. C.C.JENSEN Benelux B.V., Ivan Partono, Sept 2010 Page 31
  • CLEAN OIL PON Power, Gen-Set seminar, Fuel and Engine oil BRIGHT IDEAS www.ccjensen.nl Fuel station, CIV Texel, 3x 200m³. C.C.JENSEN Benelux B.V., Ivan Partono, Sept 2010 Page 32
  • CLEAN OIL PON Power, Gen-Set seminar, Fuel and Engine oil BRIGHT IDEAS www.ccjensen.nl C.C.JENSEN Benelux B.V., Ivan Partono, Sept 2010 Page 33
  • CLEAN OIL PON Power, Gen-Set seminar, Fuel and Engine oil BRIGHT IDEAS www.ccjensen.nl Benefits and ROI • More operation time, less down time • Cost savings • Maintenance excellence, lean & mean • Secured operations • Predictable budgets and work schedules • ROI (Return Of Investment) in most cases within 18 months. C.C.JENSEN Benelux B.V., Ivan Partono, Sept 2010 Page 34
  • CLEAN OIL PON Power, Gen-Set seminar, Fuel and Engine oil BRIGHT IDEAS www.ccjensen.nl Thanks for your attention! C.C.JENSEN Benelux B.V., Ivan Partono, Sept 2010 Page 35