Tight global economics, rising fuel costs and strict emission laws reduce profit in marine industry.The...
KRAL is an international manufacturer of high-quality screw pumps, flow meters and installations for all kinds of marine fuels and lube oils. KRAL is well known as a reliable and flexible partner for unique and tailor made system solutions, and has the know-how and the expertise to turn customers innovative ideas into unique solutions. Today we are already thinking of more than just tomorrow – with benefit for you and the environment.
Precise KRAL fuel consumption measurement (FCM)
About 80% of diesel engine operating costs are fuel costs. For efficient engine operation with low emissions, electronic control and monitoring systems are required. Harsh operating conditions like fluid pulsation, temperature variations and vibrations has made this impossible in the past. KRAL offers now a robust and precise fuel consumption measurement system.
With a measurement precision of ±0.1%, reproducibility 0.01% and a measurement range of up to 100:1, calibration and testing institutes assess KRAL Volumeter as the most precise displacement meters. Leading engine manufacturers and suppliers of engine control systems use the KRAL fuel consumption system. With the precise measured values, they determine the specific fuel oil consumption (SFOC) and the fuel conversion efficiency (FCE). The proven, robust KRAL FCM reduces costs and allows engine performance monitoring. The KRAL system recognises flow and temperature excesses, reverse fuel flows and circulation rate. With the help of this data, engine malfunctions can be uncovered. For more extensive analysis KRAL offers software for the data acquisition and evaluation.
In multiple engine installations the KRAL FCM indicates the fuel consumption of each individual engine on a central display. To keep the error propagation of the entire measurement system small, accurate single flow meters are essential. Low precision flow meter are not suitable for fuel consumption measurement. The KRAL BEM 1000 software allows configuring and checking the settings of the KRAL electronics BEM 300, BEM 500, BEM 700 and BEM 900. Programming, evaluating and analysing the data of your flow measurement applications can now be accomplished easily on a PC. The download of the BEM 1000 software from the company’s website is free of charge.
Measuring different fuels
In SOx emission control areas (SECAs), ocean-going ships are driven by MDO. In these protected areas, stricter limits for sulfur content apply. The limits can not be achieved in HFO operation. KRAL Volumeter measure irrespective of the viscosity of the fuel, maintaining high accuracy during fuel changeover. KRAL systems are therefore suitable for HFO, MDO and the continuous mixing stages.
KRAL innovations make an important contribution to protect environment
KRAL is currently making important contributions to environmental protection for shipping. The most direct way of protecting the environment is not to consume fuel in the first place. KRAL Volumeter help operators to save fuel. Providing real-time fuel consumption data to the bridge will result in reduced fuel consumption by improving operating behavior.
Fuel consumption per nautical mile
KRAL BEM 800 FCM integrates the highly accurate KRAL Volumeter, BEM 500 electronics and on-board GPS data for a precise evaluation of the fuel usage per nautical mile. KRAL BEM 800 FCM is developed for marine applications which need a fuel consumption display and storage capability that is able to process GPS data and speed. The 15in or 8in display shows measurement results either numerous or graphical. Multi engine systems can be visualised on one screen. The system has a data storage capacity for one year data logging. The new product integrates analysis templates to show the history of recorded events and voyage based statistics. Recorded data and results can be transferred via USB and e-mail.
Advanced fuel consumption monitoring and diagnostic system
Operators of marine diesel engines want to know the fuel consumption and the specific fuel oil consumption (SFC) at different engine loads. The SFC is given in g/kWh. To check the specific fuel oil consumption, the operator needs the precise value of the fuel mass flow rate. KRAL fuel consumption measurement indicates mass or volume values very precisely. The operator determines the power of the engine via measurement of the speed and the torque on the drive shaft itself. BEM 820 ADV is able to process the torque and rotation speed and to calculate with the fuel consumption the SFC.
Many marine vessels do not provide fuel consumption indication in the wheelhouse. KRAL electronics BEM 810 RD is a remote display that receives fuel consumption measurements from the KRAL BEM 500 electronics and displays these data on a large dimmable screen. As an option BEM 810 RD can integrate GPS data to display fuel consumption per nautical mile. The usability of BEM 810 RD is simple. One button provides the ability to dim the display. The second button is used to select the required information from BEM 500. The communication between BEM 810 RD and BEM 500 is done using the Modbus RTU protocol. BEM 810 RD may also be used as a repeater unit for BEM 800 FCM, BEM 820 ADV and BEM 840 EKW.
Bunkering monitoring system for LFO and MDO
Ship operators want to double check the amount of bunkered fuel. KRAL electronics BEM 830 BKR integrates the KRAL Volumeter and BEM 500 for bunkering applications. The bunker fuel quantity can be presetted. The bunkering time remaining is visualised by the system. BEM 830 BKR also offers the opportunity to print a receipt of the bunkering data.
A reliable system
More than 400 fuel consumption measurement systems sold to various industries prove the quality and benefit of the KRAL system. About 60% of the systems are used to measure heavy fuel oil, 30% are measuring diesel oil, and the remainder are operated in dual fuel mode. Besides the marine industry, where the systems are installed on cruise liners, container and tanker vessels, fishing and tug boats, and inland ships, operators of stationary power plants, railway companies and diesel engine manufacturers also rely on the KRAL fuel consumption measurement system.
Compact KRAL pump stations
There are critical applications in which a second pump is prescribed for security. Reliability through a standby pump which is always available, is the basic idea of the dual station. After the changeover, the switched-off part of the station block is depressurised and the pump can easily be removed. The ship’s engine continues to run, the production process is not interrupted, the heating system continues to operate.
KRAL pump stations series DKC/DMC
KRAL double stations have been proving their worth for 40 years, and have been so extensively developed that a totally new generation has emerged. KRAL double stations series DKC/DMC are particularly beneficial to those companies that construct and complete their pump stations from individual components. In this case, the space saved amounts to more than 50%. There are an impressive number of functions combined in the compact stations, taking up minimal space.
KRAL pump stations series DKB
KRAL pump stations series DKB are of special interest to booster module manufacturers. DKB are compact and space-saving units, beneficial for the ‘hot side’ of a booster module where no strainers and pressure-maintaining valves are required. You save valuable space and avoid extensive pipework.
KRAL Volumeter series OMA as accessory
The KRAL Volumeter series OMA can be mounted very easily to any KRAL DKC/DMC pump station. Since all DKC/DMC pump stations are already prepared for the installation of the new precision flowmeters, the OMA can be subsequently purchased as an accessory and simply screwed with very little effort. This saves time and money. The KRAL Volumeter series OMA has an integrated bypass. Maintenance and cleaning work is possible without service interruptions. Switching to bypass operation can be done manually or by electric actuator. The KRAL Volumeter series OMA is easily maintained and can be drained over the sump of the pump station. For reading or interpretation of the data KRAL provides the proven electronics BEM 300 and BEM 500.
Hermetically sealed magnetic couplings
Heavy fuel oil (HFO) usually has a high proportion of abrasive components. This may damage the mechanical seals of the pumps. Increased leakage and total pump failure may result. The only way to drastically improve HFO capability is to completely replace the mechanical seals with a different technology. As an alternative, which has been tried and tested in practice and which is also suitable for the new double stations, KRAL provides pumps with magnetic coupling. KRAL pumps with magnetic coupling are hermetically sealed and suitable for temperatures up to 250°C.
KRAL meets low sulfur SECA/ECA regulations
Numerous regulations like MARPOL Annex VI or EU Directive 2005/33/EC are now in lace to protect
our environment through significant reduction of sulfur in marine fuels. These regulations limit the sulfur emissions in sulfur emission control areas (SECA/ECA).
Reduction of sulfur oxide emissions
MARPOL Annex VI will reduce the sulfur oxide (SOx) emissions from ships from current 4.5% to 3.5%. This rule will come into operation from 1st January 2012. Then progressively to 0.5%, effective from 1 January 2020. The limit in SECAs is currently 1.0%, and will be reduced to 0.1%, effective from 1 January 2015. Since 1 January 2010 ships at berth in community ports must operate with a maximum sulfur content for fuels of 0.1%. The future regarding new SECAs is uncertain. In march 2009 the US Environmental Protection Agency proposed new SECAs at the US and Canadian coast.
DMZ – a new marine fuel
The sulfur contents of the marine fuels DMA and DMB are specified in ISO 8217. According to ISO 8217 (fourth edition 2010) the viscosity of DMA is 2.0mm²/s at 40°C. DMZ has a minimum viscosity of 3mm²/s at 40°C and is otherwise identical to DMA. Not only the sulfur content but also the viscosity is important for engine and pump manufacturers. Based on recent experiences with engine and pump damages, a new distillate DMZ has been added to ISO 8217.
Is DMZ the solution?
The actual prize and the availability of DMZ is uncertain. Standard marine fuels are still first choice. DMA has a viscosity of 2.0mm²/s at 40°C. Engine room temperatures can be higher than 40°C. Published worst case scenarios show viscosities down to 1.1mm²/s. KRAL is a proven manufacturer of reliable pump solutions. It is well known that if KRAL announces a solution, this solution is well calculated, tried and proven.
KRAL pumps for low sulfur fuels
Today KRAL offers a wide range of pumps for low sulfur fuels. The casings and the spindles are treated, coated and hardened using new technologies. As an option, the pumps and pump stations are available with magnetic coupling. With a magnetic coupling the pumps are hermetically sealed. The engine room will remain clean and safe.
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