This document summarizes a seminar on best practices for fuel and engine oil management for generator sets. It discusses specifications for diesel fuel and issues related to water contamination in fuel such as corrosion, microbial growth, and clogged filters. It also covers engine oil specifications and additives as well as common problems like short drain intervals and sludge formation. The document promotes the use of CJC fuel and oil filtration systems to remove particles and water from fuel and oil, extending drain intervals and reducing maintenance costs and environmental impacts. Case studies of customers using CJC systems for generators are also presented.
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PON Power, Gen-Set seminar, Fuel and Engine oil
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Gen-Set seminar, best practice for fuel & engine oil management.
C.C.JENSEN Benelux B.V., Ivan Partono, Sept 2010 Page 1
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PON Power, Gen-Set seminar, Fuel and Engine oil
BRIGHT IDEAS
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Content:
1. Introduction C.C.Jensen
2. Diesel fuel EN590 (low sulphur):
• Specifications and SECA (Sulphur Emission Control Area).
• Problems and trouble shooting → high water content, bacterial growth, impurities in fuel tanks.
• CJC Filter Separator, purification of fuel (removal of water and particles).
• Best practice, preventative maintenance.
• Related issues; Biodiesel(EN14214)
3. Engine oil:
• Manufacturer specifications, EGR (Exhaust Gas Recirculation), oil additives.
• Problems and trouble shooting → short drain intervals, bore polishing, sludge formation.
• CJC Fine Filter, 3µ particles & soot removal, Acid neutralisation, TBN stabilisation, Fuel dilution.
• Best practice, drain interval extensions →savings and environmental impact.
• Related issues, engines on bio fuel → MAN diesel 8.5MW (Oostende), ABC diesel 2.5MW (Kesteren).
4. Application studies and related projects:
• KLM Equipment Services, Schiphol Airport Amsterdam, GPU (Ground Power Unit), Gen-Set fuel and engine oil.
• APM Terminal, Port Said Egypt, RTG (Rubber Tired Gantry), Gen-Set Engine oil.
• CIV Texel fuel station.
5. Benefits and ROI (Return Of Investment)
6. Presentation of demo units PTU and HDU, seeing is believing.
C.C.JENSEN Benelux B.V., Ivan Partono, Sept 2010 Page 2
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1. Briefly about C.C.JENSEN A/S
• A limited company, family owned
– established in 1953
• >200 employees in Denmark
• 10 subsidiaries + 2 sales office Filter Division
abroad, with > 80 employees
• Production of:
• Ship windows → 15%
• Casting of ship propeller
→ 15%
• Oil & Fuel Filtration → 70%
• Export: 65%
Window & Casting Division
C.C.JENSEN Benelux B.V., Ivan Partono, Sept 2010 Page 3
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The Filter Premises
Løvholmen 18 Løvholmen 9 & 13
The new Factory in Hesselager
C.C.JENSEN Benelux B.V., Ivan Partono, Sept 2010 Page 4
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The Filter Production
Off-line Filtration Systems
From OEM Products to Special Solutions
C.C.JENSEN Benelux B.V., Ivan Partono, Sept 2010 Page 5
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Production per Year
Filter Inserts > 120,000 Filter Units > 11,000
C.C.JENSEN Benelux B.V., Ivan Partono, Sept 2010 Page 6
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www.ccjensen.nl WORLDWIDE NETWORK
Europe
Active on
5 continents
- in more than
40 countries
North America South America Africa & Middle East Asia & Australia
C.C.JENSEN Benelux B.V.,Presentations, Sept 2010
A/S, General Ivan Partono, C.C.JENSEN Worldwide Network, No. 1-14, - August 2009 Page 7
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2. Diesel Fuel
EN590 describes the physical properties that all
automotive diesel fuel must meet if it is to be
sold in the European Union, Iceland, Norway and
Switzerland.
Allows the blending of up to 7% fatty acid methyl ester with 'conventional' diesel - a 93/7 mix.
Source: Wikipedia
C.C.JENSEN Benelux B.V., Ivan Partono, Sept 2010 Page 8
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EN590 itself is a high quality low sulphur fuel which, in the “modern”
engines will perform well, will give a good clean burn, has a slightly lower
density resulting in a slightly higher fuel consumption which is more or less
compensated by it’s somewhat higher heating value and its lubricity is due
to additives acceptable. It’s even the case that the so-called “modern”
engines are required to use fuel with less than 50 ppm anyhow.
EN590 sulphur free fuel has the following advantages:
a) it leads to a reduction of SO2 and particulate emissions.
b) it is necessary for future engine emission control technologies such as
EGR (Exhaust Gas Recirculation) and exhaust after treatment systems
(it is also specified by the engine manufacturers for modern new engines).
c) it would allow for cost effective retrofit after treatment systems such as
DPF (Diesel Particulate Filters) and selective catalytic reduction of NOx.
Source: IVR report on the impact on implementation of low sulphur fuel in
seagoing vessel per 1-1-2010 and inland navigation per 01-01-2011.
C.C.JENSEN Benelux B.V., Ivan Partono, Sept 2010 Page 9
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Sulphur Emission Control Area
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Point of interest: Water, Total Contamination and FAME (bio fuel).
C.C.JENSEN Benelux B.V., Ivan Partono, Sept 2010 Page 11
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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 Benelux B.V., Ivan Partono, Sept 2010 Page 12
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Water Creates Wear and Corrosion
Fuel pump worn out by cavitation Wear and corrosion of injector
C.C.JENSEN Benelux B.V., Ivan Partono, Sept 2010 Page 13
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Water Creates Bacteria Growth
Water contamination can result in bacteria growth
Bacteria growth in oil tank Diesel with water and bacteria
C.C.JENSEN Benelux B.V., Ivan Partono, Sept 2010 Page 14
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Examples of microbial contamination (diesel bug)
Fuel in-line filter blocked by organic contamination.
Fuel tank, traces of micro organism colonies.
There are known to be over 20 species of
fuel bugs that can contaminate your fuel
storage tank.
The physical effects of microbiological contamination (diesel bug) are the formation of
sludge's, bio-films (slimes) and surface or interfacial scum's. These occur in the fuel tank
and also manifest themselves as material which block filters. A single cell weighing one
millionth of a gram can grow into a bio-mass of slimy algae mats weighing 10 kilograms
bio-
within twenty four hours. Source: penninepump.co.uk
C.C.JENSEN Benelux B.V., Ivan Partono, Sept 2010 Page 15
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Gen-Set fuel filter clogged with organic contaminations.
C.C.JENSEN Benelux B.V., Ivan Partono, Sept 2010 Page 16
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Water Removal – Separation
Centrifuge
Coalescer Separation
C.C.JENSEN Benelux B.V., Ivan Partono, Sept 2010 Page 18
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CJC Filter Separator
Guaranteed 3 micron
particles removal
Below 100ppm water
content
Low maintenance [KISS
approach]
Easy handling and
installation
Proven technology
Extensive product range
Solid build and long
technical working life
World wide supply and
service
Sustainable solution
C.C.JENSEN Benelux B.V., Ivan Partono, Sept 2010 Page 19
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Best Practice
• Pre-conditioning of bulk/storage tanks, purification
of fuel before usage.
• Tank breathers, avoid ingress of moisture.
• On board Gen-Set fuel tank purification, removal of
water (condensation) and contaminations.
• Fuel tank design enhancing water and
contaminations to settle to designated place, the
lowest part can be accessed with cleaning
equipment, precaution of ‘dead stock’ in the tank.
• Environmental friendly, minimize usage of
hazardous chemicals (diesel bug killers) and waist
disposal.
C.C.JENSEN Benelux B.V., Ivan Partono, Sept 2010 Page 20
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3. Engine manufacturer specifications
Diesel fuel according DIN51601 or EN590, few other specifications:
• Max water content 0.1%
• Max fuel temperature below flash point
• Max viscosity to injectors 20cSt
• Fuel filter (duplex) 20micron absolute
Engine oil prescriptions:
• API grade CJ-4 (and ECF-3)
Note: Introduced in 2006 for high-speed four-stroke engines. Designed to meet 2007 on-
highway exhaust emission standards. CJ-4 oils are compounded for use in all applications with
diesel fuels ranging in sulphur content up to 500ppm (0.05% by weight)
API - American Petroleum Institute (http://www.api.org/)
• SAE viscosity grade, mono- or multigrade e.g. 15W40
SAE - Society of Automotive Engineers (http://www.sae.org)
• Oil sampling intervals of 250 running hours
C.C.JENSEN Benelux B.V., Ivan Partono, Sept 2010 Page 21
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Oil Additives
Anti-Oxidant or Oxidation Inhibitors e.g. zinc dithiophosphates.
Anti-Foam e.g. methyl silicone polymer.
Detergents and Dispersants → polar molecules that envelope sludge and
soot particles e.g. calcium and barium sulfonates.
Rust /Corrosion inhibitors → polar molecules that are chemically attracted
to steel or iron surfaces, forms a barrier film to repel water e.g. organic
acids, esters and amines.
Anti-Wear (Extreme Pressure) → offers enhanced lubricity at the
boundary contact between surfaces e.g. Zinc Dialkyl Dithiophosphate (AW),
Sulphur-phosphorous (EP).
Pour Point Depressants → allow oil and lubricants to flow at very low
(wintertime) temperatures.
Viscosity Index Improvers → reduce the rate of viscosity change as oil
temperatures vary during service.
Reserve Alkalinity → Base Number, alkalinity agents neutralizes acids.
Source: Noria, Oil Analysis Basics.
C.C.JENSEN Benelux B.V., Ivan Partono, Sept 2010 Page 22
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Typical issues high speed diesel engines
related to contaminations:
• Bore polishing
• Compression ratio, wear on valves and piston rings
• Injectors failures
• Incomplete combustion → exhaust gas emission
• Fuel pump life time
• Sludge formation in the oil sump
• Lube oil pump breakdown
• High engine oil consumption
• Short engine oil drain interval, caused by:
TBN (Total Base Number) decrease, Fuel dilution, Soot content, Viscosity
increase, Oil change procedure, Oil degradation.
C.C.JENSEN Benelux B.V., Ivan Partono, Sept 2010 Page 23
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CJC Fine Filter type HDU, before and after filter.
C.C.JENSEN Benelux B.V., Ivan Partono, Sept 2010 Page 24
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CJC Filter Element
Depth Filtration
Cut-down used CJC filter insert type A 27/27
C.C.JENSEN Benelux B.V., Ivan Partono, Sept 2010 Page 25
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Gen-Set, ABC engine (2500kW) on Waist Vegetable Oil → Bio CHP application
C.C.JENSEN Benelux B.V., Ivan Partono, Sept 2010 Page 26
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MAN 8.5MW Gen-Set on Bio-fuel, recycled Waist Vegetable Oil.
C.C.JENSEN Benelux B.V., Ivan Partono, Sept 2010 Page 27
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Best Practice
• Correct oil drain procedure
• Life time extension engine parts
• Cleaner combustion → less emission
• Best choice (engine) oil type
• New oil deliveries and storage
• On board automatic oil level control system
• Additional by-pass or off-line depth filtration
• Periodical oil sampling and trend analysis
• Less used oil disposal
• Predictive and proactive maintenance
C.C.JENSEN Benelux B.V., Ivan Partono, Sept 2010 Page 28
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4. Related projects
Ground Power Unit, 140kVA → “ Power by the Hour “
C.C.JENSEN Benelux B.V., Ivan Partono, Sept 2010 Page 29
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Retro-fit equipments:
• Automatic oil level
control system
(make: Groenveld)
• Fuel Filter Separator
type PTU15/12(BLA)
• Engine oil fine
filter(3µ) type
HDU15/25(A)
C.C.JENSEN Benelux B.V., Ivan Partono, Sept 2010 Page 30
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Benefits and ROI
• More operation time, less down time
• Cost savings
• Maintenance excellence, lean & mean
• Secured operations
• Predictable budgets and work schedules
• ROI (Return Of Investment) in most cases
within 18 months.
C.C.JENSEN Benelux B.V., Ivan Partono, Sept 2010 Page 34
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Thanks for your attention!
C.C.JENSEN Benelux B.V., Ivan Partono, Sept 2010 Page 35
