Bunker Summit

Greece 2007

SEA-Mate Analyser and Blender

May 11 - Session 6: Under The Spotlight:

New Technologies and innovation in the bunker sector
12:10 12:20
Terry Robinson
Web: http://www.maerskfluid.com/
Email : CPHMFTMKT@maersk.com

PAGE 1
 Maersk Fluid Technology
-
Business & Marketing Plan 2007

(Draft)

PAGE 2
 The Challenge

Usage of rotating machinery in marine environments has grown exponentially over the past
30 years there are about 45,000 vessels in operation, ~ 5,800 being Container Vessels
Tramp Freighters Liner Freighters Container Vessels
Off-shore exploration / production platforms
Oil & Gas supply vessels
FPSO
Crude, Gas and Product Tankers
Ever growing fleet of marine vessels providing transportation of goods in a global economy
Crew size availability of man-power
Ever more complex technologies involved
Growing environmental awareness / concerns
Rapidly growing costs both capital and operational expense:
Daily Running Cost biggest metric on the deep blue seas
#1 cost factor = fuel
#2 cost factor = lubricants
#3 cost factor = maintenance

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 The Challenge Cont..

Heavy Fuel Oil

Specification issues include:-
Density, Viscosity, TSP, CCR, Flashpoint, Water , H2S, cat fines, Sulfur
Sulfur content in SECA (Sulfur Emission Control Areas)
Operational constraints in waiting for sample results if specifications are marginal.
Speed of Bunkering V de-bunkering of out of spec Fuel (i.e. Sulfur marginally higher
than 1.5% or cat fines above 80 PPM)
Monitoring of filter / Separators to ensure removal of cat-fines
Main Engine System Oil
Contamination (from Stuffing box)
Decreased fuel efficiency with increased contamination.
Cylinder Oil (Two Stroke)
Need for varying TBN based on HFO Sulfur content
i.e. if HFO S=low then waste of BN and possible ring deposits
Wear related to Cylinder Feed rates
Hydraulic Oils and other Lubricants
Base line and wear trending
Maersk Fluid Technology, Inc. May 11, 2007
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 The Solution

Optimize use of hydrocarbons on-board / -site equipment:

reduce consumption of fuels and lubricants
improve the environmental impact
optimize lubricant formulation / cost-engineer lubricant performance

Introduce tools to enable Predictive Maintenance and Incipient Failure Detection:

near real-time analyses of hydrocarbons to assess equipment health
apply artificial intelligence to analyze / fingerprint scenarios
enable state-of-the-art data communication pathways to enable on- and off-board
interpretation, analysis and product procurement: Remote Monitoring & Diagnostics

Introduce the SEA-Mate line of products:

on-board / -site analyses of elemental concentration in hydrocarbon fluids
on-board / -site analyses of water contamination in hydrocarbon fluids
on-board / -site analyses of other critical components: sulphur, cat-fines, monomers,
asphaltenes, viscosity, density, heat content, etc.
On-board/ -site blending of lubricants and fuels as operating conditions and product
availability dictate
PAGE 5
 Engine Technology: issues

Normal Operation

PAGE 6
 Engine Technology: issues

Low BN cylinder oil /

High-S fuel

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 Engine Technology: issues

high BN cylinder oil /

low-S fuel

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 Liner Vessel 101

and then there are all other hydrocarbons that require close monitoring
ancillary equipment:
gear oils, hydraulic fluids, etc.
heavy fuel oil

marine distillate fuel

TP engine oil bow thruster

hydraulic oils
ME cylinder oil
ME system oil
stern tube oil

stern thruster
hydraulic oils

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 SEA-Mate Analyzer

Fast and Simple

Elemental Analysis System:
Simple, accurate and efficient on-board/-site testing of heavy fuel oil (HFO) before it comes on-
board for Sulphur ( 0.01%) and cat-fines down to protection limit in less than 10 minutes.
Quality Testing of HFO for waste oils etc.
Engine Wear Characteristics of scrape-down samples with the following elements: Calcium,
Vanadium, Chromium, Iron, Nickel, Copper, Zinc, Barium, Lead and Phosphorus.
Simple-to-understand user interface, which includes use of bar-code reader for logging a) time,
b) sample location, c) sample fluid / associated specification for quality control, and d) sample
bottle ID, removing errors via manual input

Maersk Fluid Technology, Inc. May 11, 2007

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 SEA-Mate Analyzer

Fast and Simple user interface

Non destructive testing of samples,

Simple bar code system to pair Sample
locations with unique sample bottle IDs,
Specification limits are pre-assigned to
location IDs,
Traffic light (Green / Amber / Red) sample
results against specifications,
Comparative trending of results,
Password security with full results and time
stamped traceability,
Based on open standards communications
for future proofing,
Possible communications with other
onboard systems for comparative trending
(engine load, speed, humidity, etc),
Enterprise communications protocol for
possible business system integration,
Artificial intelligence model capability for
data processing and pattern matching

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 SEA-Mate Analyzer

Status:
Gen-II:
Demonstration of commercially available system to both internal and external parties has yielded
large interest from both OEMs and maintenance specific companies
Maersk Oil & Gas, Maersk Contractors, MAN B&W, Wrtsil, Mitsubishi Heavy Industries, Vestas,
and DONG / Energi2
Field Trials:
Presently 10 SEA-Mate Gen-II Analyzers installed on-board vessels and a Power Generation
Barge in Mindanao with very encouraging results
fully updated Gen-III SEA-Mate to be used with Blender trial on Sine Maersk
Gen-II SEA-Mate deployed on Power Barge PB-118 to support SEA-Mate BoB-trial.

Gen-III:
to be included with all
Blending-on-board
installations
includes capability to
analyze cat-fines down
to 5 ppm for bunkers
first prototype to be
available by 2Q2007,
vessel trial to begin
3Q2007

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Lab correlation + Gen-3

PAGE 13
 SEA-Mate Blender

Optimised Fluid Solutions

SEA-Mate Blender:
tool to provide on-board / -site blending of optimized fluids, namely main engine
cylinder oil from used system oil to increase operational flexibility and reduce
daily running cost
blends fluids of widely different physico-chemical characteristics to consistent,
high-performance lubricant specifications
Delivers tailor-made lubricants to meet the demands of the vessel and fuel

Why use used system oil?

Constant replenishment of system oil leads to improved system oil condition:
Reduces cooling bore deposits
Improves main engine bearing lubrication
Improves engine efficiency
Reduces waste

PAGE 14
 SEA-Mate Blender - Layout

Fuel Lubricator Day Tk.

Cylinder Oil

Emissions Hold. Tk.

SEA-Mate
Analyser

SEA-Mate
Blender
Main Engine

Scavenge Oil
Used
Additive
System Oil
Fresh
System Oil

Sludge Tk. ME Sump Clean Tk. Add. Tk.

PAGE 15
SEA-Mate Blender - installed

PAGE 16
 SEA-Mate Blender Status

SEA-Mate Blender:

Presently 2 SEA-Mate blenders installed on-board Sine Maersk and PB-118

power Barge in Mindanao, Philippines

In addition, off-board blending continues to be tested on Caroline Maersk

MAN B&W evaluation / comparison of commercial cylinder lubricants vis--vis

blended cylinder oil, prove performance even in part superior to commercial grades

Blender re-design to reduce costs, improve reliability, operations and installations to

be completed by end of 2006, with prototypes to become available by May 2007

Installation of next generation blenders on A.P. Moller Maersk container fleet to

begin Q2 2007

A second series of trials will investigate the feasibility of blended oil solution to
allow running on low and zero sulphur fuels in environmentally sensitive areas

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 SEA-Mate Blender Features

Several design options available dependent on requirements

SEA-Mate Blender - Key features:

Blended oil properties are PLC controlled
Mass flow meter or volume flow meter options available
Capable of blending range of fluids
Base oil feed stream up to 1735cSt @5oC
Additive feed stream up to 100,000+cSt @5oC
Typical finished fluid for HFO operation *
TBN range 35-80mgKOH/g
Viscosity typically 16.5cSt (figure dependent on feed streams)
Volumes up to 2.5m3/hour possible

Classification bodies approvals

ABS approval granted for several Maersk vessels
Discussion ongoing with other classification bodies
Approval granted on a per vessel basis
Pre-Type approval next generation prototypes approved by ABS and Lloyds
Register
Type approval design in progress

* TBN and viscosity range is dependent on feed streams used. For LSFO alternative additive technologies can be introduced

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 OEM Approvals

Negotiation with OEMs regarding blended oil specification and approvals underway with
the following proposals received:

The blender unit must as a minimum fulfil the following requirements for the blended
product:
o TBN min. 40, ASTM D2896
o Stable TBN ( 2 mgKOH/g), ASTM D2896
o Stable viscosity ( 2%, SAE50), ASTM D445
o Oil stability (no precipitation after one month storage)
o No abrasive particles, e.g. sand, dust etc, ICP/XRF measurements
o Water: max 0.2%, ASTM D1744
o Flash point: min. 1900C, ASTM D93
o TAN: 0 mgKOH/g, ASTM D664

These properties must be tested in an independent lab, and each test result verified by
at least two samples taken at the same time.

PAGE 19
 Thank you!

Web: http://www.maerskfluid.com
Email : CPHMFTMKT@maersk.com

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