Slow Steaming

Benefiting retrofit solutions from MAN PrimeServ

2 Slow Steaming
Slow Steaming
Introduction

Out of the total operational costs of a ship, fuel costs account for by far the high-
est proportion. In view of the global economic situation and the rising oil prices,
shipowners and charterers are looking for solutions to cut costs by reducing fuel
consumption. Low load operation, also well-known as “slow steaming”, represents
the currently most effective and popular measure to cut fuel costs and, in conse-
quence, the total operational costs for increased competitiveness in the market.

Low load operation down to 10-20% MCR is possible

with MAN B&W engines and there is an increasing
trend to operate in these very low engine load ranges.
As the engines were not designed for this operational
profile, various retrofit modifications to the engine can
compensate for this.

Benefits from slow-steaming upgrades

Apart from running at part-load, there are a number
of ways to further increase the financial benefit from
slow steaming. These measures enable reductions
in fuel and lubricating oil as well as an improved en-
gine performance, adding significant further gains to
the annual savings achieved by slow steaming itself.
Such solutions are:
„„ Turbocharger cut-out
„„ Slide fuel valves
„„ Alpha Lubricator upgrades
„„ Engine derating with the option of new propeller
design.

Content
This brochure outlines the currently offered two-stroke
retrofit solutions that support slow-steaming opera-
tion. More detailed information can be obtained by
contacting your local MAN PrimeServ office:

MANDieselTurbo.com/PrimeServEarth

Slow Steaming 3
 Turbocharger Cut-Out
The big money saver for low load operation

come by installing a turbocharger cut-out. Thereby,

the performance of the remaining turbocharger(s) will
be improved from running at higher revolutions, which
again reduces the fuel oil consumption further.

The solution with swing gates offered by MAN Prime-

Serv gives the operator the option of disengaging one
of the turbochargers for low load operation whenever
needed. This flexibility allows optimised turbocharger
efficiency at both part and full load.

Reception in the shipping world

The solution has been widely accepted in the shipping
world and has become a standard retrofit choice for
many larger vessels with three and four turbochargers.
Lately, service experience has shown good SFOC
Benefits for slow-steaming operation savings for engines equipped with two turbochargers,
„„ Substantial SFOC savings at low load and turbocharger cut-out is expected to be an attrac-
„„ Flexible solution allowing both low and full load. tive upgrade for them as well.

Operating principle Fuel oil savings potential

Reducing speed is the most effective measure to Depending on how the individual engine was de-
reduce fuel costs. However, at low load, the turbo- signed, substantial SFOC savings can be achieved by
chargers are operating below their optimal range. This installing a turbocharger cut-out. The relative savings
has an adverse effect on their running performance, stated below are based on the latest experience from
which limits the potential fuel oil savings. On engines engines in service and should be seen as a guideline.
with two or more turbochargers, this can be over-

Obtainable load range after one turbocharger cut-out

No. of TC 1 of 2 2 of 3 3 of 4

Relative savings, g/kWh (at 25% engine load) 6 5 4

Load range 10-35% MCR 10 - 66 % MCR 10 - 74% MCR

4 Slow Steaming
Slide Fuel Valves
Eliminating deposits when slow-steaming

Benefits of slow-steaming operation

The slide type fuel valve is the latest design and is
a must-have for slow-steaming operation. Reducing
the vessel speed reduces fuel costs, but slide valves
are a necessity for proper large-scale slow-steaming
operation. The slide type design improves the com-
bustion process and eliminates the carbon deposits
in the exhaust gas ways that typically occur from low
load operation with the traditional fuel valves. Such
deposits accumulate rapidly, and engines with tradi-
tional fuel valves will require more maintenance and
frequent cleaning of the gas ways.

„„ Improved low load performance

„„ Better combustion process in less deposits throughout the gas ways and a re-
„„ Reduced fouling of gas ways and exhaust gas boiler duction in overall emissions. The visible smoke level
„„ Reduced fouling of piston top land. is also greatly reduced as a result of the improved
combustion. The need for maintenance is reduced
Operating principle with the cleaner gas ways, and testing procedures
The slide fuel valve reduces the amount of soot and are simpler thanks to the improved design.
gives better combustion properties. This is achieved
with a more advanced design that eliminates the sac Reception in the shipping world
volume in the past types. The spray pattern of the Slide fuel valves are now standard on new MAN B&W
fuel is also further optimised leading to an improved engines but are also considered a must-have among
and more complete combustion process. This results most shipowners and operators for older engines.

Cleaner exhaust gas ways

The two photographs illustrate a key benefit of retro-
fitting the slide fuel valve. The first photo shows an
exhaust valve bottom piece with substantial deposits
caused by an incomplete combustion process. The
right-hand side of the photo shows the same valve
seat after the slide fuel valve has been installed. The
photo was taken after 890 running hours with the new
slide fuel valve. No additional cleaning or scraping
was done when retrofitting the new type of fuel valve.

Comparison of slide fuel valve before and after retrofitting

Slow Steaming 5
 Alpha Lubricator Upgrade
Lube oil savings from slow-steaming

By adapting the new lubricator layout, a complete lubri-

cation optimisation at all engine loads is now possible.

Cylinder oil feed rate

Specific feed rate [g/kWh] Reduction factor [-]
2.00 1.0

1.80 0.9
High load breakpoint
1.60 25% load breakpoint 0.8
Reduced load breakpoint
1.40 0.7

1.20 0.6

1.00 0.5

0.80 0.4

0.60 0.3

0.40 0.2
Breakpoint at 15 revolution/injection
corresponding to ~35% engine load
0.20 0.1

~10% Engine load ~25% Engine load

0.00 0.0
35 40 45 50 55 60 65 70 75 80 85 90 95 100
Engine rpm (of MCR) [%]

The new lubricator layout reduces the engine power

level at which the algorithm, controlling the cylinder oil
feed rate, changes. The “breakpoint” is moved to the
left. The Alpha Lubricator upgrade enables the cylin-
Benefits of slow-steaming operation der oil feed rate to follow a lower curve. The marked
„„ 20-50% cylinder lubrication oil savings at low load area in the figure above corresponds to the potential
„„ More accurate feed rate control at all engine loads lubrication oil savings from upgrading the system.
„„ Minimising over-lubrication at low load, reducing
deposits, hence improving the cylinder condition. Scope of delivery
The Alpha Lubricator upgrade comprises a new MCU,
Operating principle the latest software, and new improved lubricators ei-
In 2012, a new layout of the Alpha Lubricator in ther as complete lubricators or as kits, which can be
new MC engines has been introduced. Along with a used for newer unworn units.
number of design improvements, the injection volume
and frequency has been changed in order to optimise
the cylinder oil consumption at low load. Now, the Savings example on a 12K98MC-C
Alpha Lubricator upgrade is introduced as a retrofit
Lubrication oil consumption at
solution, optimising cylinder oil consumption in en-
10% engine load:
gines in service.
Before upgrade 240 litres/day
After upgrade 100 litres/day
A consequence of substantial over-lubrication at low
load is generating deposits on the piston crown and Yearly savings EUR 42,000
rings, increasing the risk of damage to the cylinder (at 6,000 hrs/year &
liners. In addition, over-lubrication generates excess EUR 1,200/ton lub. oil)
costs for unnecessary lubrication oil. The Alpha Lubri-
cator upgrade is a major improvement of the system. Lube oil savings potential

6 Slow Steaming
Derating
Changing engine rating

Vessels designed around 2008 were designed for Engine modifications

high service speeds. Many of these vessels are now Derating will involve changing/modifying the below
becoming increasingly uneconomical in today’s slow- main engine components:
steaming market. Derating offers the possibility of „„ Fuel and exhaust cam positions (timing) & size
changing the specified maximum continuous rating „„ Fuel atomisers
(SMCR) to match the requirements of vessels expect- „„ Fuel valves (slide fuel valves must be installed)
ed to remain slow steaming. „„ Shim’s height between x-head and piston rod
„„ Wave cut of cylinder liner (removal of wear edge)
Benefits „„ Re-matching turbocharger(s)
„„ Reduced SFOC at all loads „„ New technical file
„„ New refurbished turbocharger „„ NOX measurements on board for parent vessels.
„„ Reduced power consumption (propeller exchanged).
Operational profile
Principle The main prerequisite for a successful derating project
Derating is the procedure of changing the rating is a thorough investigation in which the expected fu-
(power and speed) of an engine. Choosing the op- ture operational profile of the vessel is analysed.
timum engine rating (or layout) is today, as standard, „„ Maximum ship speed, after modification
performed on newbuildings in order to ensure that „„ Design speed, after modification
the required vessel speed is reached by an optimum „„ Operational speed distribution by running hours.
combination of propeller and engine layout. In retro- The benefit of any derating project is critically depend-
fit applications, derating is offered to ensure that the ent on the quality of the operational profile.
engine rating (layout) is changed to meet the current
ship speeds in today’s slow steaming market. Chang- Propeller exchange
ing the SMCR of an already built engine (derating) Derating often includes an exchange of the original pro-
permanently changes the performance of the engine peller with a new propeller with an increased diameter
by limiting the power output and thereby the vessel’s optimised for the revised engine layout with reduced
maximum speed. engine speed (rpm). Typically, combining engine derat-
ing with an exchange of the existing propeller will have
a positive influence on the project payback time when
compared to derating the main engine alone.

Slow Steaming 7
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. Copyright © MAN Diesel & Turbo.
1510-0199-00ppr Sep 2012 Printed in Denmark

MAN Diesel & Turbo

PrimeServ
MAN DieselCopenhagen
& Turbo
Teglholmsgade 41
2450 Copenhagen SV, Denmark
Phone +45 33 85 11 00
Fax +45 33 85 10 49
30
[email protected]
[email protected]
www.mandieselturbo.com

MAN PrimeServ – a service brand of MAN Diesel & Turbo