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Thursday, May 9, 2019 

Heinzmann says that increased demand for a reduction of environmental pollution, as well as an increase in engine efficiency for marine applications, has necessitated advanced technical solutions for the Swedish icebreaker fleet, which the company was able to provide through its common-rail system retrofit with associated control and monitoring equipment.

The Swedish Maritime Administration (SMA) examined the technical possibilities of an advanced fuel management system to meet the environmental guidelines and increase efficiency. The project started with the retrofit of the 40-year old icebreaker Ymer. Heinzmann reviewed the feasibility and the expected performance of implementing a CR-retrofit system to the ship’s five main Pielstick 2.2 engines generating 3.5 MW each. As a proof of concept, one of the five main engines was retrofitted with the Heinzmann CR-system to determine the impact on efficiency and emissions.

The system installation involved no major modification to the engine itself; it comprised the complete replacement of the fuel system, the mounting of a local operation panel and the integration of the Heinzmann control, monitoring and safety system into the ship’s automation system. A second main engine with original hydraulic governor-based configuration was operated under comparable conditions in order to rate the improvements. During a two-year-test period it was proven that the targeted 5 % fuel saving could be met with the CR-system.

Further fuel savings of 2.5 % were achieved with an additional turbocharger upgrade. In addition, visible smoke disappeared completely. The vibration level fell by 30% and the maintenance costs decreased.

The remaining four main engines were retrofitted three years later. Further fuel saving potential was planned by reducing the engine speed in part load from 485 rpm fixed speed down to 360 rpm variable speed. As a so called 'Green Drive', this load dependent speed mode resulted in a further fuel saving of more than 4 %. As a side effect the lube oil consumption decreased by 50 %.

After completion of the commissioning of all five engines, the successful integration into the ship automation system was verified during sea trials.

The Heinzmann CR-system has now proven itself throughout three seasons under challenging and harsh operating conditions. Further retrofits for the remaining SMA vessels are under consideration, following a confirmed total fuel saving of 11%.

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