First swing gate on SULZER engine
As a response to an inquiry of a customer, who was looking for a more price competitive alternative to the automatic (two-stroke engine) turbocharger cut-out device sold by Wärtsilä, Tekomar has tailored a retrofit upgrade solution with the well-known swing gate valve designed by MAN.
Based on a contract between MAN Diesel & Turbo and Tekomar, the components were sourced directly from MAN and the swing gate valve was successfully installed and commissioned on a RTA62 type engine.
Needless to say that the exactly same savings are achieved as with the OEM solution, as there is no difference in the thermodynamics of the engine with either solution, but the investment cost is reduced by up to 50%.
For customers aiming at an even more cost efficient solution, Tekomar also offers the own designed Tekomar Turbo Cut (TTC), a manual, flexible turbocharger cut-out device. For more information please see the product page here.
Get a handle on Engine Performance
Tekomar Performance Evaluation Software is about to change the way of handling engine performance data.
Our approach of analysing and processing marine engine performance data in day to day operation has hit the markets in all regions with great success. Tekomar has received orders for 150 software sets in the first four months since availability of this new tool.
There are two main ingredients, which are making the software different. Firstly the tool puts the ship operator in the driver seat. The shipping company can utilize the pre-processed thermodynamic data and reports, without having to call maker’s engineers on-board for expensive one time assessments. By using the application on a regular basis, engine operators will less likely face unforeseen situations, and the maintenance level of the engines can be greatly improved.
Second, the tool ensures a systematic and absolutely transparent monitoring and optimising of fuel oil consumption and other cost drivers by registration and indication of changes over time on a particular engine. Moreover it allows the direct comparison of engines (vessels) in a fleet.
Customers who have deployed this new tool acknowledge that Tekomar Performance Evaluation is a major, long time overdue development of the way of working with engine performance data - comparable to the step from typewriters to modern word processors.
Please visit the product page here
Consulting on IMO Tier I compliance
A large number of Sulzer engines built between 1990 and 2000 that are now subject to investment for expensive IMO Tier I upgrades, would technically need either no or only slight permanent adjustment to comply with the IMO Tier I NOX requirements, or in other words to run within the required 17g/kWh limit.
As informed earlier (see article below), Tekomar has developed own technical methods to assist customers in getting the engines built between 1990 and 2000 to comply with the IMO NOx Tier I requirements. The process of having the very cost efficient method for Sulzer brand engines verified and certified, has shown that within the given set of rules and due to self-interest of different parties, no satisfactory “approved method” could be brought to the market.
The definitions made by the IMO body, to introduce the idea of using a system of “approved method” as such is very good, as with this way, once certified, no more extensive NOx measurements on board are needed.
However it seems that the entire framework might have a weak point, leaving the ship owners no other option but to invest in an OEM-approved solution, which from a technical perspective would not be necessary.
A large number of engines could technically be brought to the required emission level with measures as simple as permanently blocking the fuel injection timing on its zero position, and a number of engines would even fulfil the requirements as they are, without any adjustments. Nevertheless these engines might be or are listed to be mandatory subject to install the available "approved method", and the ship-owner is obliged to spend money for a potentially over-engineered solution.
Tekomar now offers a consulting package for ship-owners to have particular installations assessed. We also aim to discuss with clients concrete steps for an approved way with measurement and confirmation of IMO Tier I compliance on vessels in service. In case that more ship owners are interested in joining hands, Tekomar would also start to offer real on-site NOx measurements, communication with the classification society on behalf of the client and establishment of the required technical files.
Outside the box
"When we started Tekomar we asked ourselves where in the market we wanted to be positioned: either at the troubleshooting and maintenance level where there are hundreds of other competent companies, or at the top level of knowledge where there are only OEMs? We knew that we had the skill to go straight for the top, and saw there we would be able to shape the market," says Thomas.
The latest issue of Shipping & Marine magazine features Tekomar as independent, innovative and flexible provider of Engineering and Services.
Please read more here (external link): Shipping & Marine
Awarded more Turbo Cut orders
The continuing high demand in the shipping industry for cost efficient operation optimization methods led to strong sales of Tekomar's engineered products, with a steeply increasing order intake during second half of 2012. Tekomar uncompromisingly strives to offer straight forward solutions to reduce operational cost effectively at minimum initial investment resulting in shortest possible payback time.
The latest example of this successful approach is the development of the Tekomar Turbo Cut. In December 2012 orders for another 9 Turbo Cut were signed. 3 of them are already installed now. For the 6 other kits, the material is delivered within 20 days after the order, ready for installation by the crew.
The Turbo Cut is a manual but flexible turbocharger cut-out solution, enabling the operator to cut out / in within one hour engine stand still. It can be ordered as a complete package including both, material and installation, or as a material only ”do-it-yourself” kit. The latter decreases the already low initial investment for the slow steaming solution even further. Tekomar Turbo Cut can be installed on all brands of 2-stroke engines having more than one turbocharger.
More details about the Tekomar Turbo Cut can be found on our products page
The position of being an independent 3rd party – not having to defend an own diesel engine design – is becoming one of Tekomar’s main strengths.
Customers are increasingly utilizing our consultancy servicesin technical matter related disputes with their suppliers or service providers. Just recently Tekomar was engaged in a case about technical effects on a 2-stroke engine in Asia.
Our aim is helping to ensure increased reliability of diesel engines by contributing to technical transparency in the industry with independent expert knowledge.
Strong order intake on engineered products
All the Tekomar engineered products are well received in the market. Very cost efficient design and tremendous saving potential are the drivers for decision makers.
The most recent addition to the order book is four Mechanical Lubricator Upgrades on Hans Jensen lubricators for B&W engines. This Tekomar designed solution enables operators to lubricate engines with a load dependent characteristic, instead of the original engine speed dependent lubrication. It is saving our customers large amounts of expensive cylinder lubricating oil; especially at lower engine loads.
Furthermore, six CLU1 cylinder lubricator upgrades, one automatic turbocharger cut-out device as well as one Tekomar Turbo Cut (TTC) were ordered.
The deliveries to four different customers will be done within the remainder of this year.
First orders for Performance Evaluation Software confirmed
Tekomar has launched during this year’s SMM Hamburg the new and unique software, which enables ship-operators to independently manage and evaluate engine performance data. The resulting optimization potentials can directly be turned into reduction of their entire fleet operating costs.
Despite the fact that the delivery start of the software is planned for November this year only, the first customer orders have been received in advance.
Tekomar believes that this new, highly structured way of collecting and managing engine performance data will quickly become a standard in the industry. In the same fashion like planned maintenance systems have been introduced on close to all ships operated today.
For shipping companies, being serious about looking into all aspects on optimization of fuel- and lube oil consumption, a structured approach on engine thermodynamics and corresponding adjustments is crucial. Our solutions is to evaluate engine performance based on shop test data as reference and latest thermodynamic calculations to make service readings comparable – to the engine’s own reference, but also to other engines of any brand or make in the fleet. This is the direct way to realise concrete, down to earth savings.
For more information, please visit our product page here
Tekomar joins EMISA
Tekomar is new member of EMISA (the European Maritime Independent Suppliers Association). With this membership we want to support EMISA's engagement for the promotion of free and fair competition in the business with service and engineering work for existing marine equipment. Please find the press release here.
New Engineered Products launched
The Tekomar Performance Evaluation software makes our Experts' thermodynamic calculations and baseline comparison available to operators. This is applicable in the whole operational range, be it slow steaming with Turbo Cut, Auxiliary Blower active, or Service load. Our product is a very simple to use yet comprehensive tool that gives you immediately a judgement of the engine's physical performance. It can be used on-board as well as in a superintendent office to monitor the performance of all managed engines in the whole fleet. The normalization of all relevant measurements allows a comparison of any engine regardless of type or make. Download the brochure
After the successful Cylinder Lubrication (CLU1) Upgrade for Sulzer RTA engines, Tekomar has implemented on the same control platform the Tekomar Mechanical Lubricator Upgrade for B&W MC engines. An electronically controlled actuator is engaged on the offset shaft and allows that the feed rate can be set accurately based on a load dependent lubrication characteristic. Same as in current engine designs. Download the brochure
Shop-test fuel consumption
The fuel consumption of a 2-stroke marine engine is the biggest cost driver during operation. It is measured and approved to comply with contractual obligations during the factory acceptance test at the engine builder premises.
Tekomar offers independent third party plausibility checks of the specific fuel consumption evaluated during the test run, the verification of deployed measurement equipment, expert thermodynamic analysis and independent measurements if required. Our service aims at reconfirming measured fuel consumption levels, turbocharger matching and NOx emission levels at shop-test, preferably during testing of a parent engine. With this information, ship owners have also the solid basis for further bench-marking of the engine during service.
First CLU1 Upgrade in Operation
Tekomar has successfully commissioned the first CLU1 Upgrade system on an 8RTA84C 2-stroke main engine.
This system replaces the existing mechanically controlled cylinder oil flow regulation of older RTA-engines. It permits precise maintaining of the desired oil feed rate over a wide load range. Even at lower engine load cylinder liner over lubrication can thus be avoided.
The electronic lubrication controller allows exact setting of the target feed rate by a simple user interface. A flow control valve replacing the mechanical gear is the connection to the existing cylinder lubrication arrangement. The measured effective oiler speed is again used as input for the closed-loop control. This upgrade allows substantial savings in cylinder lubrication oil expenditures, especially for engines that are not operated at high load at sea.
|Situation before the upgrade||Adapter block and valve installed||New lubrication arrangement||Speed Pick-up on lubricator shaft|
|Inside the lubrication controller||Controller box mounted||Control panel, feed rate set||Confirmation trial succeeded|
Tekomar discontinues trading of spare parts
Damen Schelde Marine Services (DSMS) and Tekomar have agreed on a strategic partnership in diesel engine spare parts. Tekomar is technology partner for DSMS and will support DSMS in building up new suppliers, assessing present suppliers, and achieving high quality standards.
DSMS has 70 years of experience in spare parts handling and manages a large stock of 2- and 4-stroke engine parts for all brands. The cooperation will ensure high availability and provide the ship and power plant operators access to competitively priced spare parts with high reliability in service. All in line with Tekomar’s aim to offer products and solutions for the best available price-to-lifetime ratio in the market.
Tekomar developed Tier I approved method for 2-stroke engines built between 1990 and 2000
Many ship owners are currently frustrated by having to retrofit their main engines to meet NOx emission standards with only one choice, namely the solution introduced by the engine designers.
Based on a strong market demand and the currently one sided situation, Tekomar decided to help out and to develop an own approved method, which will enable operators of those engines to choose a very cost efficient method, lowering the retrofit costs to be below 10’000 EUR per engine.
The target engines to seek for approval in a first step are of the types RTA84C, RTA84CU, RTA72, RTA72U, RTA62, RTA62U and RTA58T of Sulzer brand.
Retrofit solutions for other engine models and other engine brands will be studied, and, if applicable, brought to the market as well.
Tekomar Engineering staff has deep knowledge in engine design, engine thermodynamics and emission technologies, and can therefore grant for technically sound solutions to meet all emission regulation standards - for optimized cost expenditure. In order to underline full compliance, Tekomar decided to go the full way through all approvals, having an own approved method, certified by the relevant classification societies.
The approved method - as well as the ready to implement solution - has been designed and developed recently. Tekomar aims at launching the product as soon as possible, in order to enable all customers to have a free choice between two solutions, and of how much to spend for it.
The launching date of the product is planned to be in the first quarter of 2012, after passing engine designers’ verification, and class societies’ certification process.
For more information regarding development, verification and certification, please refer to this link: MARPOL Annex VI, Approved Method
Service Upgrade Products successfully launched
Tekomar has invented, designed and successfully launched its first two engineered service upgrade products. The target for both products is to provide operators and owers with a very cost efficient solution, generating savings in operational costs from the first day after the installation. Because of the low investment costs, both products will achieve a reasonable pay-back time of one year or less.
Tekomar Turbo Cut is ordered and to be installed early 2012 on vessels of two major shipping companies. This solution is to provide improved engine performance as well as better fuel consumption in part load operation of the main engine.
Tekomar CLU-1 upgrade is ordered and to be installed in the endo of 2011 on vessels of two major shipping companies. This solution is to provide an improved cylinder lubricating oil consumption particularly in part load operation of the main engine.
Currently there is a strong demand for both products in the market, and Tekomar expects to receive a larger number of additional orders within the remainder of this year.
Low NOx tuning on ENDESA power plants
Tekomar has successfully developed and verified a NOx reducing up-grade package on two Sulzer 9RTA76 engines at Las Salinas (Fuerteventura) and Jinamar (Gran Canaria) Power Plants, Canary Islands. Acting in cooperation with Marine Diesel Services, Tekomar was responsible for the solution engineering and tuning of the engine.
ENDESA GENERACIÓN demanded a solution for lowering the NOx emissions to the new limit of 2300mg/Nm3 at reference condition of 15%O2, dry base, complying with the regulation introduced by the Government of the Canary Islands. ENDESA had the options to install an SCR (selective catalytic reduction) system requiring several million of Euro of investment cost, or to take the engines out of service, having to cover the electrical demand in Fuerteventura and Gran Canaria with less efficient engines.
Due to the excellent results, other two 9RTA76 engines will be converted into low-NOx configuration in a short period.
The solution proposed by Tekomar fulfils the new regulation, having only minimal overall cost impact for the customer. It was worked out together with ENDESA and includes a minor limitation of the power output without impact on the operation, adapted components as well as modified injection layout and equipment. All this leads to an optimized engine, fulfilling the requirements:
- NOx emissions below the new limit
- Low component temperatures for long component lifetime
- Investment cost on a reasonable level
Engineering solutions on a high expertise level with optimized cost impact and without compromising on reliability is what is defined to be one of the core competence of Tekomar in its aims to add value to their customers operation.
5 year contract signed
Tekomar has been awarded a 5 years performance and reliability Contract for 2 vessels equipped with the Wartsila RT-flex58T main engine and with MAN auxiliary diesel engines. The Contract includes technical support, trouble shooting, and maintenance of the main engine as well as the auxiliary engines.
The customers (Beltship Management Limited) directive to Tekomar was “to maintain the engine room machinery at the highest possible reliability and to avoid any off-hire day’s caused by the main engine, auxiliary engines and associated ancillaries”.
In order to achieve this target Tekomar together with the Beltship have worked out a system of permanent online monitoring of the engine performance, this will be combined with regular on-site inspections carried out by attending Tekomar engineers and enhanced feedback from the vessels Chief Engineers in a reporting format developed by Tekomar. This co-operation is importantly focussing on optimizing maintenance schedules by utilising condition based maintenance in a forward looking programme to enhance the reliability and operational costs in the best way.
This contract is another milestone in what is defined to be the core competence of Tekomar in its aims to add value to their customers operation.
New building supervision contract
Tekomar was awarded a contract from an international shipping company to conduct the new building supervision of their RT-flex50 new building program at engine builder's site. The inspection plan, which consists of 16 different stages, is tailored in the way that the optimal manufacturing- and engine tuning quality is achieved. The investment in supervision will be the insurance to have the engines in the right shape before going into commercial service and contributes to avoid potential troubles in operation.
Tekomar Germany and Tekomar Norway opened
Both as fully owned subsidiaries of Tekomar Group Ltd, are Tekomar Norway AS and Tekomar Deutschland GmbH located where our customers are. On the Norwegian west cost in Kopervik and in the centre of Germany's shipping business: Hamburg. Both offices are operational and our representatives are ready to serve you. Find more contact details here.
Strategic Partnership: Goltens
Goltens and Tekomar have agreed on a strategic partnership which forms the best competitive market alternative for independent diesel engine repairs and services through high tech engine competence and global service. Read the full press release here.