Professional Documents
Culture Documents
2010
Slow steaming
a viable long-term option?
A U T H O R : A n d r e a s W i e s m a n n , G e n e r a l M a n a g e r I n n o v a t i o n & B u s i n e s s D e v e l o p m e n t , Tw o - s t r o k e , W r t s i l S e r v i c e s
The slow steaming of merchant years, resulting in record-high up and idling of vessels, and all kinds of
ships, particularly container ships, deliveries of new ships cost reduction measures.
has become a much discussed topic. Z The global nancing crisis
It is a topic that affects the entire Z The sudden fall in ship values Fuel consumption
industry, from cargo owners, carriers, Z High fuel costs The biggest single cost factor in merchant
ship owners and operators, to Z Increasing operating costs (manning, shipping, particularly for container and
equipment manufacturers. lube oil, maintenance) other large vessels, is the fuel oil. And the
Z Falling freight rates, which in turn also easiest way to reduce this cost is to reduce
Background for slow steaming impacts charter rates. the ships speed. The typical propulsion
A combination of factors have led to the All of these things have put the entire system for larger merchant ships is a low-
past two years becoming hugely challenging value chain starting from cargo owners speed two-stroke main engine, directly
for certain sectors of the global merchant to the carriers, ship managers, ship owners, driving the xed-pitch propeller via the
shipping industry. These factors include: nancing institutes and equipment suppliers propeller shaft. The ships speed is, therefore,
Z The downturn in the global economy, under big pressure. The industry has had reduced by lowering the speed of the
resulting in reduced transportation to quickly adjust, which has resulted in engine and propeller. The power required
capacity demand a sharp slow-down in new ship orders, from the main engine, however, correlates
Z The substantial global order book for cancellations of already conrmed orders, disproportionately with the ships speed
new tonnage, a legacy from the boom the delaying of new ship deliveries, laying- (Figure1).
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Ships
providers will be done on a business to 250 25
business basis. These negotiations will in
Mio USD
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The optimal load range of the two-stroke and recommendations were summarized in Poor combustion
engine lies between 70-85%. The fuel the beginning of 2009 in a Wrtsil Service Z Poor atomisation
eciency of the engine, its operational Bulletin about low-load operation. Z Higher sac volume: injected volume
parameters, the specication of the In general, it was concluded that the ratio, increased likelihood of dripping
turbochargers, coolers, auxiliary systems, modern Wrtsil two-stroke engines are Z Increased fouling and carbon
exhaust gas boilers, and so on, are chosen able to reliably operate in all load ranges deposits likely.
and optimised for that normal load range. between 10% CMCR and 100% CMCR Cold corrosion
It is natural, therefore, that when the without major modications, if the Z Caused by condensation of corrosive
engine is operated continuously in a load operational parameters and precautions, as vapours
range below or even far below 60%, the documented in the Operating Instructions Z Possible when observing very low
overall system is no longer fully optimised. and in the mentioned Service Bulletin, are engine temperatures during very low
As the industry didnt use slow steaming properly followed. By adhering to these load operation.
during the previous 20 years, nobody had recommendations, the potential risks Fouling
really good long-term experience with inherent to such operation will be mitigated. Z Of the exhaust system, turbochargers,
continuous low-load operation of todays exhaust boilers
generation of new engines. Therefore, Expressed technical concerns Z Of the scavenging air space due to
marine engineers who daily operate the To varying degrees across the low load excess cylinder oil.
engines, technical managers, as well as range, dierent engine conditions can be Apart from these engine related concerns,
engine builders, were initially reluctant to observed. The possible consequences of concerns have also been voiced about
fully embrace the concept. continuously operating at reduced load eciency losses (e.g. propeller, turbo
Based on requests from carriers and without taking the recommended chargers, shaft generators, heat recovery
operators, Wrtsil has investigated the precautions are: systems) and the accelerated deterioration
various concerns that have been raised, Lower air ows of condition and performance (e.g. fouling
including concerns on component Z A problematic area after the auxiliary of the hull and propeller due to reduced
temperatures, fouling of exhaust systems, blowers cut out / before they cut in ship speed, stern tube seals, shaft bearings).
turbochargers, etc., and has addressed Z The possibility of very high exhaust,
them in eld investigations and through and thus component temperatures. Summary of recommendations
discussions with operators. The conclusions Wrtsil RT-ex engines are better suited
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24 184
22 182
Reduction of fuel and CO2 (tons/24hrs)
20 180
Fuel savings with Upgrade Kit CO2 reduction with Upgrade Kit
normal BSFC BSFC with Upgrade Kit
Fig. 4 Additional fuel savings at different speeds using the Slow Steaming Upgrade Kit.
than the Wrtsil RTA engines for at the upper limit (8595C). A high 450C, after the cylinders should be
continuous loads down to 10% due to their cooling water temperature will reduce avoided during the period following the
unique electronically controlled common condensation and thermal stresses. By auxiliary blower cut out or before cut
rail injection system and exible exhaust passing of the fresh water generator will in. This may cause hot corrosion and
valve control. The selective fuel injector most likely be necessary to maintain burning of the exhaust valve seats.
cut-o at low load enables improved the cooling water temperatures. As a countermeasure, the auxiliary
injection characteristics, resulting in Z Normally the cylinder oil feed rate is blower may be switched to continuous
reduced carbon deposits and, therefore, load dependant, and no adjustment is operation.
less fouling of both the exhaust gas boiler needed. However, frequent piston Z Another concern during continuous
and turbocharger. underside inspections are recommended low load operation is the accumulation
However, for both engine designs the to monitor piston running conditions of unburned fuel and lubricating oil in
recommended measures in the Operating and signs of over- or under-lubrication. the exhaust manifold, as such deposits
Instructions and Service Bulletin have to In a recently released Wrtsil Service can ignite after the engine load is
be implemented and followed to ensure Bulletin, we have described this increased again. This may result in
reliable continuous low or ultra low load characteristic and shown certain severe damage to the turbocharger
operation. In short, the recommended observed symptoms on the piston rings due to sudden over-speeding. Wrtsil
precautions are as follows: during low load operation. When these therefore recommends that the engine
Z Ensure the injector nozzle condition symptoms occur, a temporary increase load be periodically (twice a week)
is correct. This is standard engineering in the cylinder lubricating feed rate will increased to as high as possible (at least
practice but should be given more help stabilise the situation and recover to 70%) for a minimum of one hour in
attention than in normal operation the reliable piston-running performance. order to blow through any accumulated
Z Maintain higher fuel temperatures and Z It is important that the temperature carbon deposits. Whilst operating at
aim to achieve lower viscosities, of the exhaust gas after the cylinders is these increased loads, turbocharger
12 / 13 cSt kept above 250C in order to reduce washing and soot blowing of the
Z Keep the LT cooling water temperature cold corrosion. If the exhaust gas economiser should be undertaken
at 36C in order to maintain the temperature drops below this value, in order to reduce fouling
optimum scavenge air temperature, and the engine load should be increased Wrtsil continues to observe several
the jacket cooling water temperature Z High exhaust gas temperatures, above parameters, by collecting customer feedback,
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service attendance feedback, and through in the low-load range, this solution
structured eld testing. In this way new provides full exibility (the engine can be
trends can be detected early, and in depth operated from 10 to 100%) and decreases
experience on the long-term behaviour of the risk of engine fouling and excessive
the engine and components at low and component temperatures. This solution is,
ultra low load operation can be gained. therefore, best in a long-term scenario,
If required, we will publish additional whereby both slow steaming and nominal
recommendations and solutions via speeds are, or might be, required as the
Service Bulletins. engine can operate at any time up to its
maximum installed power for full sea speed.
Optimisation solutions This retrot is available for ships tted
As mentioned above, the Wrtsil RT-ex with Wrtsil RTA and RT-ex low-speed
engines are better suited for continuous engines having more than one turbocharger.
low-load operation, due to their high One such installation of the Slow Steaming
exibility in engine control, which allows Upgrade Kit took place in October 2009
optimisation of the parameters in the onboard a vessel with a 12-cylinder
lower load ranges as well. Such features Wrtsil RT-ex96C main engine with
include the selective fuel injector cut-out at three turbochargers. The measured fuel
very low loads, as well as the Delta-Tuning, savings were 812 g/kWh in the optimal
which optimises the specic fuel oil load range.
consumption below 75% load. For new The benets and operational exibility
engines, Low-Load Tuning provides of this solution have been recognised by
additional exibility and a further reduction several major operators and carriers, and
in specic fuel consumption at lower loads Wrtsil has received a number of orders
by optimising turbocharger eciency for for the Upgrade Kit.
the lower load range, and through by If the operational prole of a vessel is
passing a part of the exhaust gas ow at changed for a longer period to slow
high loads. steaming, and engine loads above 6070%
In addition to these inherent or optional are not required at all, the blinding of one
features in new engines, Wrtsil is also of the turbochargers can be more cost
continuously seeking upgrade- and retrot eective, achieving the same BSFC
solutions that t specic operational reductions as the exible Slow Steaming
requirements, and which provide optimal Upgrade Kit solution. However, this clearly
engine performance and eciency. limits the engines load range (1060%,
The owners and operators of Wrtsil upper limit depending on the amount of
two-stroke engines have the following turbochargers), and the vessel has no
solutions available: possibility to achieve full sea speed if
required. Also, the recommended periodical
Wrtsil Slow Steaming Upgrade Kit operation at higher loads to blow out any
This automated exible turbocharger accumulated carbon deposits in the system,
cut-out solution extends the optimised and cannot be carried out with full eectiveness
reliable load range of the engine for due to the upper load limits with a blinded
continuous low load operation, and o turbocharger.
signicantly reduces the specic fuel
consumption in the low load range. These Permanent de-rating of the engine
fuel savings are achieved by cutting-o one If the operational prole of a vessel is
of the turbochargers, which in turn leads changed for long-term operation at reduced
to increased scavenge air, and thus better speeds and lower engine loads (e.g. 515%
ring pressures. The turbocharger cut-o is reduction), a de-rating of the engine might
done in a controlled and fully automated be the best solution considering fuel
way. The fuel savings, as well as the load at consumption, reliability and operational
which the turbocharger can be cut-o, exibility. The scope of the solution
depends on the number of turbochargers. depends upon the required de-rating. This
For example, for a Wrtsil RT-ex96 solution is applicable for all engine types.
engine with three turbochargers, the load
range with a cut-o turbocharger is Combination with a propeller
about 1060%. modication
In addition to a major reduction in When the engine is de-rated or
BSFC (Brake Specic Fuel Consumption) continuously running at low-load, an
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optimised propeller to better match the Monitoring and control options elements from the monitoring system and
new operation conditions might achieve For the continuous monitoring of cylinder combines the measured data with an
additional fuel eciencies. The optimal liner wall temperatures, Wrtsil has for intelligent logic in the Wrtsil Engine
specication can be oered by Wrtsil many years already oered the so called Control System (WECS). This enables
Services, combining the support from its MAPEX-PR system, which allows optimal cylinder pressures to be controlled
two-stroke engine and propulsion experts. the temperature trends of the liners and adjusted automatically. Using this
(corrected by actual engine loads) to be automatic control, further fuel eciency
Pulse Lubricating System monitored. The system also gives early optimisation in the range of 12% is
Wrtsil introduced the Pulse Lubricating warnings should they exceed the upper or possible.
System (PLS) a few years ago as its standard lower limits.
cylinder lubricating system for all new Recently introduced by Wrtsil, the CONCLUSION
engines. The system was also introduced Intelligent Combustion Monitoring system Looking at slow steaming from a wider
as a retrotting solution known as the continuously monitors cylinder pressures perspective, this article describes several
Retrot Pulse Lubricating System (RPLS) and several parameters during the full important considerations covering the
and was installed widely on large bore combustion cycle. It enables the trending global shipping industrys view, the drivers
engines. and analysis of the monitored data in order for slow steaming, the commercial aspects,
Earlier lubricating systems might have a to understand the engines performance, and the technical concerns for achieving
problem in achieving optimal timing and as well as that of the condition of further eciency solutions whilst slow
distribution of the cylinder oil, especially components in the combustion chamber. steaming. We can conclude that slow
in the lower load ranges when combined This system gives additional information steaming has a number of very obvious
with a cut-out turbocharger. The RPLS about combustion performance, advantages, and will, therefore, probably
system ensures precisely timed injection of particularly during low load operation. continue to be used by the industry for
the lube oil into the piston ring package, Wrtsil oers also an integrated a long time. Conversely, slow steaming
which optimises the lubrication, while the monitoring system, which transmits throws up several challenges, which need
piston ring pressure is increased and the specied data from ships to Wrtsils to be properly addressed, and the
speed decreased during low load operation. operation data server; the data is regularly operational recommendations need also
In addition, the PLS and RPLS analysed and evaluated by engine experts to be followed. Wrtsil is supporting its
will reduce the specic lubricating oil and reports, together with expert customers with all required advice and
consumption by 2040% and in so doing, recommendations, are provided to instructions. Furthermore, Wrtsils
further increase lube oil savings (low-load the technical managers of the ships. upgrade and retrot solutions oer
operation in itself already saves a substantial For RT-ex engines, Wrtsil will also customers the opportunity to further
amount of cylinder lube oil). introduce the Intelligent Combustion optimise the overall eciency of the ships
Control system in early 2011, which takes engine and propulsion.
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