Lubricating systematically

“Pulse Lubricating System”

Soon all 4,000 TEU-vessels of the Hansa Mare Reederei will be retrofitted with an addition to the main engine. In future a newly developed “Pulse Lubricating System” will ensure that cylinder lubricating oil consumption on board is reduced significantly. Depending on the engine load, cylinder lubricating oil is injected into the piston chamber through the liner. The piston rings glide on this lubricant film. Here it is important that as little oil as possible is injected so as to save costs and prevent overlubrication. The oil contains additives that bind dirt, for example, and increase the lubricity. When temperatures of up to 1,800° C occur during ignition, these additives are burnt and its residues remain on top of the piston and piston rings. Burnt residues form a sort of coke, which in the worst case wipes off the lubricant film from the cylinder liner resulting in “non lubrication” with piston and cylinder liner failure as consequential damage. In daily engine operation, however, it is not only necessary to pay attention to luboil specifications, but also to the luboil consumption.

The “Alpha Lubricator” developed by engine manufacturer MAN B&W and the “Pulse Lubricating System” made by Wärtsilä/Sulzer ensure that a precisely metered amount of lubricating oil is injected. The computer-controlled system notes the position of the piston and then adds an exactly calculated quantity of lubricating oil between the first and second piston ring. This takes place at high pressure so the oil is injected in a very fine spray and the cylinder liner is moistened evenly on the surface – at precisely the site where the piston rings are located and where friction actually occurs. Up to ca. 30 % lubri­cating oil consumption can be saved with this system. Depending on the main engine output the 4,000 TEU-vessels consume approx. 900 l of lubricating oil a day or approx. 250 l less compared to present conditions.

That is Worthwhile

The installation of the “Pulse Lubricating System”, along with metering pumps and sensors as well as the required additional pipelines, pays off within a short time.
Based on the fact that Hansa Mare Reederei has already installed a MAN B&W “Alpha Lubricator” on three vessels of the 3,000 TEU-class, initial experience confirms this calculation. The savings of 0.3 g per kilowatthour specified by MAN for the engines operated on board the “Mare Africum”, “Mare Gallicum” and “Mare Thracium” are clearly achieved on those vessels. Comparing luboil consumption in 2006 with 2007 and considering the same engine output and trading pattern the current savings on the “Mare Africum” amount to 33.15%.

In addition, Hansa Mare Reederei will install a performance measuring device on the propeller shaft of the retrofitted 4,000 TEU-vessels to record the output of the engine at any time. After all, the “Pulse Lubricating System” will only be effective if the engine is run at a constant normal power of 85-90 %.

Riding crews on board

Retrofitting work on the 4,000 TEU-vessels will commence soon. Together with the inspectors of the shipping company, the representatives of the manufacturer have already taken measurements on board the “Mare Siculum” and conducted an inspection of the engine room. The components needed for retrofitting are currently being produced so that modification of the first engine can be started very soon. Wärtsilä has technically designed the system in a way that it can be installed in individual work steps while the ship is sailing. At sea the service engineers of the supplier work on board to install the piping and pumps. The port lay times are then utilised to install the injection units on the cylinders, thus avoiding any “off hire”-times.

Depending on the ports called at, the riding crew needs between a week and ten days for the modification. Vessel's engine crew provides assistance in line with their specific on-site know-how.

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