Documentos de Académico
Documentos de Profesional
Documentos de Cultura
The ISO 8217 working group took this Although the makers of separators claim the separator.Any significant reduction
into account when they developed the that their equipment should be capable in efficiency should be investigated.
2010 edition of the standard and reduced of reducing catalytic fines by around
the maximum content of combined 75%-80%, tests on fuel samples taken After centrifuging, the fuel will be
aluminium and silicon for fuels supplied from before and after separators in stored in a service tank. Settling of
to 60mg/kg, giving ship’s engines a service, have shown efficiencies catalytic fines in this tank will again
little more protection. Clearly, if a fuel substantially lower. In some cases, depend on how long the fuel is stored.
as supplied contained 60mg/kg, and the Brookes Bell have encountered this to be As this fuel will be at around 98˚C after
maximum permitted at the engine was as low as 45% and have found typical purification, some catalytic fines will
10mg/kg, a separator efficiency of 83% efficiency to be around 65%. Poor deposit out and over time the bottom
would be necessary (if 15mg/kg at the separation efficiency can be a result of of this tank will become rich in
engine was accepted, then an efficiency using incorrect gravity discs (in a catalytic fines. If the ship is in heavy
of 75% would be needed). ‘conventional’ separator), too low fuel weather, pitching and rolling, these
inlet temperature and/or too high a feed deposits may be disturbed, entering the
Fortunately, the vast majority of fuels rate. Clearly, if a fuel entering a separator fuel system and passing to the engines.
supplied have combined aluminium contained 80mg/kg combined Ordinarily the only line of defence
and silicon levels well below 60mg/kg, aluminium and silicon and the separator after the service tank is the supply
nonetheless, effective fuel treatment efficiency was down to 65% or lower, system fuel filters.
remains imperative. then the fuel leaving the separator
would contain at least 28mg/kg, well Typically, the fuel supply line to the
On board treatment above the recommended maximum of main engine will be equipped with
15mg/kg at engine injection. auto-backflush filters with a mesh size
Catalytic fines have a tendency to settle of between 35 and 50 microns
towards the bottom of a tank during The importance of correct operation (although some operators are installing
storage; this process depends very much and maintenance of separators cannot 10 micron filters in main engine
on the fuel temperature and storage be overstated. It is recommended that systems).The auxiliary engine fuel
time. In practice, settling out of catalytic the manufacturer’s maintenance systems may be equipped with 10
fines in primary (storage) tanks (where procedures are included in the ship’s micron fuel filters. However, it must not
the temperature would typically be planned maintenance schedule and that be assumed that filters will take out all
around 30˚C) is rather low and most the equipment is correctly operated. In remaining catalyst particles after
likely less than around 10% of the total addition to the proper operation and purification.
suspended catalytic fine content. So, a maintenance of the separators, regular
fuel with 80mg/kg combined drainage (‘dewatering’ or ‘desludging’) Particle size
aluminium and silicon at delivery may of service and settling tanks will assist in
be transferred from a storage tank to a the fuel treatment process. The size (and shape) of catalytic fines
settling tank with around 72mg/kg. As varies, probably due to the service life
the fuel is held at around 70˚C in a For effective residual fuel oil treatment, of the particles in the refinery
settling tank, we may expect a greater separators should be operated at processes.The data below shows the
reduction in catalytic fines but this minimum flow rate, considering range of particle sizes against the
tends to be restricted when the ship is consumption, and the fuel inlet percentage for each size range.The first
at sea and the tank is lowered and filled temperature should be 98˚C. It should column shows results from tests on a
periodically. However, when the ship is be ensured that the correct gravity disc ship’s sample and the second column
in port and consumption is low, dwell is fitted (if applicable) with reference to shows typical data according to a
time increases and settling will be the density of the fuel in use. document published by Alfa Laval, BP
improved.Tests on bottom sediment Marine and MAN B&W Diesel1.
samples from these tanks have shown It is suggested that before and after
very high levels of catalytic fines. Levels separator samples are taken when fuels
Particle size Ship Sample BP
of several thousand mg/kg are not as supplied contain more than 40mg/kg
Microns % %
uncommon. Clearly, this situation is aluminium plus silicon. Indeed, at least
potentially dangerous as if these one engine manufacturer now 0-10 31 57
sediments are disturbed by the ship recommends this testing when fuels as 10 -15 32 27
rolling and pitching in heavy weather, supplied contain more than 25mg/kg 15-35 35 15
they could pass through the fuel system aluminium plus silicon. Sending these 35 -100 0.7 1
to the engines, causing rapid wear. samples for ash, water, density and
aluminium plus silicon testing and It can be seen from the above, that the
After the settling tank, the fuel should comparison of the results between the majority of catalytic fines have a
be treated by centrifugal separation. samples, will indicate the efficiency of particle size of less than 15 micron and
1
‘Marine diesel engines, catalytic fines and a new standard to ensure safe operation – Separation Performance
Standard’, written by Alfa Laval, BP Marine and MAN B&W Diesel. UK P&I Club Catalytic Fines 2
TECHNICAL ADVICE
a considerable amount are in the range 2. Sample and test all deliveries. 6. Manually clean and thoroughly
15-35 micron. Obviously, filters with a Ensure a representative bulk drip inspect the condition of all fuel
mesh size larger than this will not sample is taken throughout each filters on a regular basis, and when
remove these small particles.The image delivery and that this bulk sample is high differential pressures are
below shows catalytic fines embedded thoroughly mixed before pouring observed or auto-backflush periods
in a piston ring.The size of these into sub-sample bottles. Failure to start to increase.
particles is up to around 15 microns. do this can result in an uneven
distribution of catalytic fines in each 7. Ensure a complete set of spare
of the sub-samples. Ensure the crew filter elements is available on board
fully understand this process. Ideally, at all times.
do not use the bunkered fuel until
the analysis results are known. 8. Regularly ‘dewater/desludge’
settling and service tanks.
3. Always operate separators with
minimum acceptable flow rate 9. Routinely open and clean the
(with consideration to bottom of settling tanks and service
consumption) and with a fuel inlet tanks (possibly to coincide with
temperature of 98˚C. Ensure the interim/special surveys, for example).
correct set up of the separator,
including (where appropriate) the 10. Routinely open and clean the
selection of the appropriate gravity bottom of primary storage tanks
Different sized particles can create disc to suit the density of the fuel. (possibly to coincide with special
different risks with the potential to Consider the operation of two surveys, for example).
cause damage at different locations in separators in parallel.
the fuel system. For example, particles 11. As well as regular scavenge/under-
can be small enough to pass through 4. As general guidance, take samples piston space inspections take main
fuel pump barrel/plunger clearances, or before and after the separators each engine cylinder oil scrape down
large enough not to enter those same time the delivery sample analysis samples every two months and send
clearances. In either case, they will not shows combined aluminium and for analyses. Monitor the trend of
cause abrasion at the fuel pump silicon above 40mg/kg. It should, iron content as this will provide
barrels/plungers, whereas those of a size however, be noted that some engine early indication of piston ring and
comparable to the relevant clearances manufacturers may recommend cylinder liner wear.
would be expected to cause damage in instigating testing at lower levels, for
way of the fuel pumps. example above 25mg/kg; OEM 12. If it becomes necessary to renew
advice and service letters/bulletins piston rings due to unusual wear,
Consider reducing risk by should be considered as applicable. obtain replicas of cylinder liners for
incorporating the following Send these samples for testing to examination. Embedded catalytic
into management systems check separator efficiency. Consider fines will need to be removed by
routine separator efficiency analysis honing of the liners to prevent
1. Insist on a maximum combined and the use of on board test kits. further wear of new piston rings.
level of aluminium and silicon in
fuel deliveries of 60mg/kg. (ISO 5. Review and adhere to the auto- 13. Keep detailed records of all the
8217:2010 or later versions).This backflush filter manufacturer’s above and of fuel consumption
may be incorporated into a time operating instructions, ensuring history. Such evidence is crucial and
charter party or an order direct with shipboard operational procedures may be decisive if fuel related
a bunker supplier. cover such requirements. engine damage is suspected.