Keep your engine fresh
MAN Diesel & Turbo The responsible way in leading technology
No-one knows large engines like MAN Diesel & Turbo. We are the world’s leading manufacturer of low and medium speed engines. And our experience dates back to the invention of the diesel engine over a century ago. PrimeServLab gives you the benefit of this unparalleled expertise. Our monitoring service, for stationary and marine engines, ensures that your engine fluids meet all relevant specifications. By performing a thorough, professional analysis, our experts can identify any potential issues, such as a faulty separator or contaminated fuel, that might be harmful to engines. With our help, you can resolve these problems promptly – extending the life of the engine and preventing major difficulties further down the line. All you need to do is provide us with a sample of your engine operating fluids, and our professionals do the rest. What’s more, you can select the services that meet your needs, from our comprehensive range of tests. In short, PrimeServLab is a simple, fast and effective way to monitor fluid quality – ensuring safe and reliable engine operation.
– More than just analysis
3
What is PrimeServLab?
Fluids such as fuel, lube oil and cooling water can have a significant impact on engine operation. With the stringent quality control provided by PrimeServLab, you can be assured that your engine operating fluids are up to standard. Why monitor engine fluids?
How it works
If an engine is to operate safely and reliably, all op-
All you need to do is send us a sample of your engine
erating fluids need to satisfy strict quality criteria.
operating fluids, using the containers provided in your
Using fluids that do not meet the engine manufac-
PrimeServLab kit.
turer’s specifications can be costly. Not only can this reduce the useful life of components, it can even pose
In our laboratory, MAN Diesel & Turbo’s specialists
serious safety risks.
perform a thorough analysis of all your operating fluids.
Prevention is better than cure. With PrimeServLab, MAN Diesel & Turbo’s experts can identify any poten-
Special features
tial problems before they become major issues.
Our service exceeds the scope of a normal analysis, as it includes unique investigation such as:
What is PrimeServLab? PrimeServLab is MAN Diesel &Turbo’s engine fluid
Checking
for contaminants in fuel oil
monitoring service, for all stationary and marine en-
Checking
for contamination of lube oil by heavy fuel
gines.
oil Evaluation
All MAN Diesel & Turbo’s analyses involve reliable methods in a laboratory environment – they are much more than quick, informal tests. These rigorous procedures address all aspects of fluid quality in detail, meaning that potential problems will not go unnoticed. Within a short space of time, we will send you a detailed inspection report. This will explain any issues and, where required, recommend possible improvements.
of the effectiveness of fuel and lube oil
PrimeServLab is offered on a modular basis, with six
separators
The benefits at a glance
Contact details
packages covering a comprehensive range of serv-
Analysis
High
MAN Diesel & Turbo
of cooling water quality
availability and reliability, through use of
ices. You can combine these packages in any way to
appropriate, high-quality engine operating fluids.
86224 Augsburg, Germany
suit your requirements.
Achievement
Phone +49 821 322-1499
of maximum component lifetime,
delivering the best possible ROI.
Fax
Prevention
[email protected]
of damage, saving repair costs and
+49 821 322-3838
avoiding downtime while work is carried out. Detection
of any substandard fluids, or any contam-
ination of fuel or lube oil Specific
recommendations based on the test
results, informed by MAN Diesel &Turbo’s extensive service experience, and taking appropriate limit val ues into account. Optimisation
of operating fluids setup (Performance
and costs optimisation)
4
– More than just analysis
– More than just analysis
5
Package 1 Comprehensive fuel analysis
This package addresses all relevant characteristics to ensure compliance with MAN Diesel & Turbo’s fuel specifications. The scope of this package is to a large extent derived from ISO 8217. Compliance with this specification is the basis for reliable engine operation. Regular quality control of fuel as bunkered is very
The scope of this package can be adapted for diesel oil
important. Occasionally fuels are supplied which do
or biofuel samples.
not comply with the basic specification, although they have been sold as complying with that specification.
Scope of Package 1
Such deviations can be of minor importance, such as
Viscosity
the wrong viscosity grade. On the other hand, they
Density
can be of crucial importance, as in the case of exces-
Water
sive water or particle content. As seen in the example
Carbon
below, a harmful fuel - which did not allow separation
Asphaltene
of abrasive particles due to excessive density - was
Elemental
sold claiming to fulfil the specification.
Sulphur
content
Catfines
content (Al+Si)
at 50°C
content residue content
analysis CHN
Not specified contaminants
Energy content
Cases are known where fuel contaminants not ad-
Today’s fuel specifications categorise fuels according
dressed in a standard analysis have caused major
their viscosity. However, in a number of cases this has
operational problems or even severe engine damage.
no correlation to quality or energy content. This can
Contaminants
Contamination
Some fuel contaminants are explicitly mentioned in
Na,
Ni, V, Fe content
In addition to a table listing standard characteristics,
of a higher energy fuel. The difference in energy con-
the fuel specification. Water and catfines can be ac-
Ash
content
a good fuel purchase specification includes a clause
tent and therefore in fuel consumption can be more
cepted to a certain level as they will be removed by
Flash
that explicitly prohibits contamination of the fuel with
than 5 %.
fuel treatment. Blending of waste lube oil into heavy
Calorific
fuel was regular practice in the past but is now strictly
FT-IR
with lube oil (Ca, Zn, P)
result in low energy fuel being sold at the higher price
point value (measured)
harmful components.
screening for chemical waste
To incorporate the calorific value in fuel purchasing
forbidden as it will harm the engine.
For example: “The fuel shall be homogeneous blends
requires a reliable determination of this value. As for-
of hydrocarbons derived from petroleum refining. The
mulas to calculate the calorific value from other fuel
fuel shall be free from inorganic acids and used lubri-
characteristics are only an estimate, we measure the
cating oils. The fuel should not include any added
calorific value in a calorimeter.
substance or chemical waste which jeopardises the
Table 1: Discrepancy between the quality ordered and the quality delivered
safety of the plant, or adversely affects the performParameter Viscosity Density
Analysis from independent lab
283 cSt / 50°C
300 cSt / 50°C
997 kg/m³ at15°C
1018 kg/m³ at 15°C
Water content
0.91 %
1.4 %
Sulphur content
0.73 %
0.69 %
15 mg/kg
54 mg/kg
Al + Si content
6
Analysis according fuel supplier
– More than just analysis
ance of the machinery, or is harmful to personnel, or contributes overall to additional air pollution.”
– More than just analysis
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Package 2 Lube oil analysis
Fuel contamination Engines from MAN Diesel & Turbo do not have de-
All engine oils are contaminated with fuel or fuel compo-
fined oil change intervals. Instead, analyses of lubri-
nents. Because of the low oil consumption of modern
cant condition are carried out at regular intervals. As
engines, these contaminants accumulate in the oil. Ex-
long as the lubricant‘s characteristics are within cer-
cessive fuel contamination can cause both black sludge
tain limits, no oil changes are required.
and piston undercrown deposits. MAN Diesel & Turbo has developed a method for determining heavy fuel
Where one or more characteristic falls outside the
contamination in lube oil (published in Diesel & Gas
specifications, however remedial measures must be
Turbine Worldwide, June 2006). This method can
implemented to avoid harm to the equipment. Such
even determine the source and mechanism of con-
measures can be a change of oil brand, or a partial –
tamination (i.e. fuel pumps or combustion chamber).
or even complete – oil change.
Scope of Package 2 Knowing the used fuel quality we are in the position to
Viscosity
recommend the most suitable oil type for your engine
Base
and your application.
Water
at 40°C
number content
Insolubles ICP:
Mg, Ba, Zn, P, B, Na, Ni, V, Al, Si, Fe, Cr, Cu,
Pb, Sn FT-IR: Fuel
oxidation, soot content
contamination: asphaltene content and in case
of contamination as well the cause of contamination
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– More than just analysis
– More than just analysis
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Package 3 Lube oil separator control samples
Proper operation of the lube oil separator is essential
MAN Diesel & Turbo has developed two methods for
for maintaining good lubricant quality and good wear
the qualitative and quantitative determination of par-
control. A standard lube oil analysis using samples
ticle contamination that enables an assessment of
taken before and after the separator does not give
separator performance to be made. One method is
any indication as to whether the separator is in good
based on filtration and evaluation of the particles as
working order. Moreover, a standard lube oil analysis
illustrated above. The second method is based on an
does not include the measurement of particles. Although
optical particle counting. The level of contamination
the parameter insolubles claims to measure particles,
defines which method is applicable.
this is a measurement of oil degradation products that can be precipitated out of the oil by the addition of a
Scope of Package 3
solvent. Only a negligible portion of these insolubles
One sample before and one after separator
sare real particles.
Water content
Contamination with particles
Table 2: Standard lube oil analysis does not reflect the effectiveness of lube oil cleaning Parameter
Before separator
After separator
Viscosity at 40°C
147 cSt
149 cSt
Water content
0.07 %
0.06 %
0.6 %
0.6 %
Insolubles (n-Heptane) Asphaltene content Vanadium content
10
0.2 %
0.2 %
53 mg/kg
56 mg/kg
Silicon content
12 mg/kg
11 mg/kg
Iron content
15 mg/kg
16 mg/kg
– More than just analysis
– More than just analysis
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Package 4 Fuel separator control samples
Fuel often contains a high proportion of very abrasive
this method cannot be applied. The MAN Diesel & Turbo
particles (e. g. catfines, rust, sand, iron) and water (of-
particle determination method gives a more compre-
ten corrosive) that must be eliminated from the fuel
hensive picture and enables an accurate judgement of
in order to avoid severe wear in the fuel system and
separator efficiency to be made in such cases.
combustion chamber. A regular survey to determine if the fuel separator is working properly is essential,
Scope of Package 4
especially when fuels containing catfines are in use.
One
sample before and one after separator
Water
content
The effective reduction of water and catfines by separa-
Catfines
tion is the clearest proof of good separator perform-
Contamination
content (Al+Si) with particles
ance. However, where the fuel does not contain catfines, or most of the catfines are of very small size,
Table 3: Example of good fuel separator performance Parameter
After separator
Water content
0.13 %
0.10 %
Al+Si content
31 mg/kg
< 10 mg/kg
Particles Particles size
12
Before separator
– More than just analysis
many
few
mainly 10 – 40 µm
mainly < 10 µm
– More than just analysis
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Package 5 Cooling water (HT, LT, NCW)
Cooling water is one of the most important operat-
Frequent on-site checks with a test kit are important,
ing fluids, but is often neglected – even though poor
but should be backed up by regular laboratory vali-
coolant condition can cause significant additional
dation to verify on-site measurements.
maintenance costs.
Scope of Package 5 Correct The
fresh water quality is very important.
lower the hard ness and concentration of salts,
the better the quality of the coolant.
pH
value
Water
hardness
Chloride
content
Concentration
Hardness causes deposits and high chloride con-
Sulphate,
of corrosion inhibitor
nitrate content
tent promotes corrosion. Chemical additives must be
14
added to fresh water in a sufficient concentration. The
Optional
concentration of additives can deplete over time, so
Anti-freeze
additives have to be regularly replenished.
Content
– More than just analysis
content
of corrosion products
MAN PrimeServ – a service brand of MAN Diesel & Turbo
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 · 2366392EN-N2 Printed in Germany GMC-AUG-02112
MAN Diesel & Turbo 86224 Augsburg, Germany Phone +49 821 322-1499 Fax +49 821 322-3838
[email protected] www.mandieselturbo.com
