Marine gas oil/ diesel fuel issues may07-comparison ptu vs centrifuge

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Benefits of fuel conditioning in long term on the life time of the diesel engine components.

Marine gas oil/ diesel fuel issues may07-comparison ptu vs centrifuge

  1. 1. CLEAN OIL MGO Filtration BRIGHT IDEAS www.cjc.dk Marine Gas Oil Related Problems Particle and water contamination • Particles generate wear on injectors and fuel pumps • Water generates corrosion, bacteria growth and wear on injectors and pump Topics: • Particles and water contamination • Function of PTU and centrifuge • Comparison tests - PTU vs. centrifuge • Features & benefits - PTU vs. centrifuge 4-stroke diesel engine C.C.JENSEN A/S, Marine Gas Oil problems, Marine Seminar – NL - May 2007 Page 1
  2. 2. CLEAN OIL MGO Filtration BRIGHT IDEAS www.cjc.dk Particles Create Erosion Wear C.C.JENSEN A/S, Marine Gas Oil problems, Marine Seminar – NL - May 2007 Page 2
  3. 3. CLEAN OIL MGO Filtration BRIGHT IDEAS www.cjc.dk Human hair: 70 µm Smallest visible particle for the naked eye: 40 µm 3 µm 1 µm C.C.JENSEN A/S, Marine Gas Oil problems, Marine Seminar – NL - May 2007 Page 3
  4. 4. CLEAN OIL MGO Filtration BRIGHT IDEAS www.cjc.dk Oil Contamination by Particles 21/19/16 20/18/15 19/17/14 18/16/13 17/15/12 16/14/11 15/13/10 14/12/9 13/11/8 12/10/7 24/22/19 2 1.6 3 2 4 2.5 6 3 7 3.5 8 4 >10 5 >10 6 >10 7 >10 >10 1.8 1.3 2.3 1.7 3 2 3.5 2.5 4.5 3 5.5 3.5 7 4 8 5 10 5.5 >10 8.5 23/21/18 1.5 1.5 2 1.7 3 2 4 2.5 5 3 7 3.5 9 4 >10 5 >10 7 >10 10 1.5 1.3 1.8 1.4 2.2 1.6 3 2 3.5 2.5 4.5 3 5 3.5 7 4 9 5.5 10 8 22/20/17 1.3 1.2 1.6 1.5 2 1.7 3 2 4 2.5 5 3 7 4 9 5 >10 7 >10 9 1.2 1.05 1.5 1.3 1.8 1.4 2.3 1.7 3 2 3.5 2.5 5 3 6 4 8 5.5 10 7 21/19/16 1.3 1.2 1.6 1.5 2 1.7 3 2 4 2.5 5 3 7 4 9 6 >10 8 1.2 1.1 1.5 1.3 1.8 1.5 2.2 1.7 3 2 3.5 2.5 5 3.5 7 4.5 9 6 20/18/15 1.3 1.2 1.6 1.5 2 1.7 3 2 4 2.5 5 3 7 4.6 >10 6 1.2 1.1 1.5 1.3 1.8 1.5 2.3 1.7 3 2 3.5 2.5 5.5 3.7 8 5 19/17/14 1.3 1.2 1.6 1.5 2 1.7 3 2 4 2.5 6 3 8 5 1.2 1.1 1.5 1.3 1.8 1.5 2.3 1.7 3 2 4 2.5 6 3.5 18/16/13 1.3 1.2 1.6 1.5 2 1.7 3 2 4 3.5 6 4 1.2 1.1 1.5 1.3 1.8 1.5 2.3 1.8 3.7 3 4.5 3.5 Hydraulics Rolling 17/15/12 and Diesel Element 1.3 1.2 1.6 1.5 2 1.7 3 2 4 2.5 Engines Bearings 1.2 1.1 1.5 1.4 1.8 1.5 2.3 1.8 3 2.2 16/14/11 Journal 1.3 1.3 1.6 1.6 2 1.8 3 2 Bearings Gear Boxes 1.3 1.2 1.6 1.4 1.9 1.5 2.3 1.8 and Turbo and others 15/13/10 Machinery 1.4 1.2 1.8 1.5 2.5 1.8 1.2 1.1 1.6 1.3 2 1.6 Source: Noria Corporation C.C.JENSEN A/S, Marine Gas Oil problems, Marine Seminar – NL - May 2007 Page 4
  5. 5. CLEAN OIL MGO Filtration BRIGHT IDEAS www.cjc.dk Water Creates Wear and Corrosion Fuel pump worn out Wear and corrosion of injector by cavitation C.C.JENSEN A/S, Marine Gas Oil problems, Marine Seminar – NL - May 2007 Page 5
  6. 6. CLEAN OIL MGO Filtration BRIGHT IDEAS www.cjc.dk 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 A/S, Marine Gas Oil problems, Marine Seminar – NL - May 2007 Page 6
  7. 7. CLEAN OIL MGO Filtration BRIGHT IDEAS www.cjc.dk Water Creates Bacteria Growth Water contamination can result in bacteria growth Bacteria growth in oil tank Diesel with water and bacteria C.C.JENSEN A/S, Marine Gas Oil problems, Marine Seminar – NL - May 2007 Page 7
  8. 8. CLEAN OIL MGO Filtration BRIGHT IDEAS www.cjc.dk LEM - MOISTURE Level Source: Noria Corp. Current Moisture Level, ppm 2 3 4 5 6 7 8 9 10 50,000 12,500 6,500 4,500 3,125 2,500 2,000 1,500 1,000 782 25,000 6,250 3,250 2,250 1,563 1,250 1,000 750 500 391 10,000 2,500 1,300 900 625 500 400 300 200 156 5,000 1,250 650 450 313 250 200 150 100 78 2,500 625 325 225 156 125 100 75 50 39 1,000 250 130 90 63 50 40 30 20 16 500 125 65 45 31 25 20 15 10 8 260 63 33 23 16 13 10 8 5 4 100 25 13 9 6 5 4 3 2 2 1% water = 10,000 ppm. ● Estimated life extension for mechanicalsystems utilizing mineral-based fluids. Example: By reducing average fluid moisture levels from 2500 ppm to 156 ppm, machine life (MTBF) is extended by a factor of 5. C.C.JENSEN A/S, Marine Gas Oil problems, Marine Seminar – NL - May 2007 Page 8
  9. 9. CLEAN OIL MGO Filtration BRIGHT IDEAS www.cjc.dk Particle Removal & Water Separation Centrifuge CJC PTU Filter Separator C.C.JENSEN A/S, Marine Gas Oil problems, Marine Seminar – NL - May 2007 Page 9
  10. 10. CLEAN OIL MGO Filtration BRIGHT IDEAS www.cjc.dk The PTU Filter Separator Outlet water content Inlet water content C.C.JENSEN A/S, Marine Gas Oil problems, Marine Seminar – NL - May 2007 Page 10
  11. 11. CLEAN OIL MGO Filtration BRIGHT IDEAS www.cjc.dk Gas Oil Problems – PTU vs. Centrifuge (1) Oil tank with dirty MGO ISO 24/22/29 915 ppm water Centrifuge CJC PTU C.C.JENSEN A/S, Marine Gas Oil problems, Marine Seminar – NL - May 2007 Page 11
  12. 12. CLEAN OIL MGO Filtration BRIGHT IDEAS www.cjc.dk Gas oil before filtration Link to Complete Report C.C.JENSEN A/S, Marine Gas Oil problems, Marine Seminar – NL - May 2007 Page 12
  13. 13. CLEAN OIL MGO Filtration BRIGHT IDEAS www.cjc.dk After the centrifuge Link to Complete Report C.C.JENSEN A/S, Marine Gas Oil problems, Marine Seminar – NL - May 2007 Page 13
  14. 14. CLEAN OIL MGO Filtration BRIGHT IDEAS www.cjc.dk After the CJC PTU Link to Complete Report C.C.JENSEN A/S, Marine Gas Oil problems, Marine Seminar – NL - May 2007 Page 14
  15. 15. CLEAN OIL MGO Filtration BRIGHT IDEAS www.cjc.dk Marine Gas Oil Test – Conclusion (1) Running very dirty MGO though a centrifuge and a CJC PTU Here are the clear facts. When Return On Investment is considered the CJC PTU wins even more, due to lower operation and maintenance costs !!! ISO code Water content ISO code Water content 24/22/19 915 ppm 24/22/19 915 ppm 21/18/16 127 ppm 16/14/11 71 ppm CJC PTU2 Centrifuge C.C.JENSEN A/S, Marine Gas Oil problems, Marine Seminar – NL - May 2007 Page 15
  16. 16. CLEAN OIL MGO Filtration BRIGHT IDEAS www.cjc.dk Gas Oil Problems – PTU vs. Centrifuge (2) Comparison of repair cost for running vessels Centrifuge or PTU2 filter separator for supplying gas oil (MGO) Two fishing vessels, working in the same conditions and both using about 420,000 litre of gas oil (MGO) per year. Both are repaired by the same local engine supplier, who wrote down the spare parts he changed on the vessels from 1998 to 2006. Spare part cost for one nozzle is app. 500 Euro without labour cost, docking and downtime. or centrifuge C.C.JENSEN A/S, Marine Gas Oil problems, Marine Seminar – NL - May 2007 Page 16
  17. 17. CLEAN OIL MGO Filtration BRIGHT IDEAS www.cjc.dk MGO Supply - PTU vs. Centrifuge (2) Vessel Kaliste, utilizing a centrifuge Baudoin engine New CAT3412 engine Sept. 98 April. 99 Sept. 99 Feb. 00 Nov. 00 Sept. 01 May 02 Jan. 03 Jan. 04 April 05 Sept. 98 May 99 July 00 July 02 April 04 Dec. 05 Oct. 98 June 99 Sept. 04 Feb.06 June 99 Oct. 04 Nov. 04 Fuel injectors replaced Fuel pump repair Turbo cleaning/revision Turbo cartridge replacements Vessel Am Aodwen, utilizing CJC PTU2 filter separator New CAT3412 engine, Dec. 1997 Sept. 98 July 99 Mar. 00 May 01 Sept. 01 Jan. 03 Aug. 04 July 05 May 00 June 01 Sept. 01 Jan. 03 July 05 C.C.JENSEN A/S, Marine Gas Oil problems, Marine Seminar – NL - May 2007 Page 17
  18. 18. CLEAN OIL MGO Filtration BRIGHT IDEAS www.cjc.dk Conclusion - PTU vs. Centrifuge (2) Vessel AM Aodwen • The “Am Aodwen” vessel utilizing the PTU2 on a CAT 3412 engine only needed replacement of fuel injectors every 2 years (in average). • In total 39 injectors were replaced in 7 years and 7 month. Vessel Kaliste • The other vessel, “Kaliste”, running a centrifuge had severe fuel injector wear problems on the first Baudoin engine. Here injectors were replaced in average every 5 months, which was an unsustainable situation for the customer. • The engine was replaced with a CAT 3412 similar to the comparison vessel. This helped a bit on the repair costs, but still the average time for replacing injectors were only 10 months. • In total 47 injectors were replaced on this CAT engine in 5 years and 3 months. Spare part cost for one injector is app. 500 Euro without labour cost, docking and downtime. • In the customers mind there is no doubt what has caused the low repair cost on the “Am Aodwen” vessel – the PTU2 filter separator! Link to the tables with repairs C.C.JENSEN A/S, Marine Gas Oil problems, Marine Seminar – NL - May 2007 Page 18
  19. 19. CLEAN OIL MGO Filtration BRIGHT IDEAS www.cjc.dk Gas Oil on Vessels - Centrifuge Vessel Kaliste, utilizing a centrifuge Baudoin engine Month and year Turbo repair Fuel injectors Time between injector Total number of replacement injectors replaced Sept. 1998 2 new turbos 12 new 12 Oct. 1998 2 turbo kits System check April 1999 Cleaning May 1999 12 new 8 months 24 June 1999 2 turbo kits 6 new 1 month 30 Sept. 1999 12 new 3 months 42 Feb. 2000 12 new 6 months 54 July 2000 Revision, 1 new 6 months 55 in 1 year 10 mth. C.C.JENSEN A/S, Marine Gas Oil problems, Marine Seminar – NL - May 2007 Page 19
  20. 20. CLEAN OIL MGO Filtration BRIGHT IDEAS www.cjc.dk Gas Oil on Vessels - Centrifuge Vessel Kaliste, utilizing a centrifuge CAT 3412 engine, new in November 2000 Month and year Turbo repair Fuel injectors Time between injector Total number of replacement injectors replaced Sept. 2001 Turbo revision May 2002 5 new 1 year, 6 months 5 July 2002 Turbo cartridge Jan. 2003 4 new 8 months 9 Jan. 2004 Pump repair April 2004 Turbo cartridge Sept. 2004 2 new 1 year 8 months 11 Oct. 2004 Turbo cartridge Nov. 2004 12 new 2 months 23 April 2005 12 new 5 months 35 Dec. 2005 Turbo cartridge Feb. 2006 12 new 10 months 47 in 5 years 3 mth. C.C.JENSEN A/S, Marine Gas Oil problems, Marine Seminar – NL - May 2007 Page 20
  21. 21. CLEAN OIL MGO Filtration BRIGHT IDEAS www.cjc.dk Gas Oil on Vessels – CJC PTU2 Vessel Am Aodwen, utilizing a CJC PTU2 Filter Separator CAT 3412 engine, new in December 1997 Month and year Turbo repair Fuel injectors Time between injector Total number of replacement injectors replaced Sept. 1998 Turbo revision Checked - OK July 1999 Turbo revision Mar. 2000 12 new 2 years, 4 months 12 May 2000 Turbo revision May 2001 Turbo revision June 2001 Turbo cartridge Sept. 2001 Turbo revision 12 new 1 year 6 months 24 Jan. 2003 Turbo cartridge 3 new 1 year 4 months 27 Aug. 2004 Turbo revision July 2005 Turbo revision 12 new 2 years 6 months 39 in 7 years 7 mth. C.C.JENSEN A/S, Marine Gas Oil problems, Marine Seminar – NL - May 2007 Page 21
  22. 22. CLEAN OIL MGO Filtration BRIGHT IDEAS www.cjc.dk CJC vs. Centrifuge Feature Centrifuges CJC Particle removal: No fixed rate β3≥75, β0.8≥2 Water removal: Yes (optional) Separation by PTU, Absorption by HDU Resin, oxidation removal: No Yes, by polar adsorption Dirt holding capacity, particles: Depending on type 4 - 6 kg per 27/27 insert Water: Separation Separation or 2 litres per 27/27 insert Adsorption capacity, resin/varnish: No 4 kg per 27/27 insert Modular system: Yes Yes Worldwide availability: Yes Yes Waste Management: Dirt and oily water Inserts of cellulose, oily water discharge Product portfolio: Many models Several insert types for different purposes OEM spare part concept: No Yes, branding possible Installation Complicated Easy Service Complicated Easy Price High Low Complete economy Bad Good Operation costs High (preheater) Low C.C.JENSEN A/S, Marine Gas Oil problems, Marine Seminar – NL - May 2007 Page 22
  23. 23. CLEAN OIL MGO Filtration BRIGHT IDEAS www.cjc.dk What CJCTM Can Do For You Three problems – one solution – one process Efficient removal of particles Efficient removal of water Depth Cellulose Filter Efficient removal of oxidation by-products Advantages Easy installation Filtration efficiency high and constant Maintenance free The result Three problems – one solution Reduced down-time and long service intervals Low operating and spare parts costs C.C.JENSEN A/S, Marine Gas Oil problems, Marine Seminar – NL - May 2007 Page 23

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