SERVICE

STX MARINE SERVICE

SOLUTIONS
THE MASTER KEY FOR DREAMS & FUTURE
THE MASTER KEY
www.stxmarine.co.kr FOR DREAMS & FUTURE
PANOCEAN Bldg., 102,Jungang-Daero, Jung-Gu, Busan, Korea
TEL | +82 51 461 2000 FAX | +82 51 461 1529
 Solutions for
Marine & Offshore contents

Cost Savings
1. Fuel Oil Drain Modifications
2. Lube Oil Quality Control Modifications
3. Alpha Lubricator Retrofits

Environment
1. MDO/MGO Operation Modifications
2. BWMS (Ballast Water Management System)
3. NOx/SOx Regulation (Tier II & Tier III) Modifications

Safety
1. Charge Air Shut-off Device Installations
2. Splash Oil Monitoring Systems
3. Bearing Wear-down Monitoring Systems

Troubleshooting & Maintenance

1. Mechanical & Electrical Troubleshooting
2. Crankshaft Recovery (Polishing & In-situ)
3. Maintenance Exchange Program

Upgrades
1. PLC Modifications
2. L16/24 MK2 Version-Up
3. FQCU (Fuel Oil Quality Control Unit)
4. NR Containment Upgrades

References: Efficiency & Proficiency

STX Marine Service Co., Ltd is the authorized STX service provider on behalf of STX Heavy Industries Co., Ltd and STX 1. E-MAS (Engine Monitoring & Analysis System)
Engine Co., Ltd, collectively referred to as STX hereinafter. STX Heavy Industries Co., Ltd and STX Engine Co., Ltd, are
2. Customized Workshop Training courses
licensed manufacturers of 2- and 4-stroke Diesel Engines and various Turbochargers for MAN Diesel & Turbo SE. MAN
Diesel & Turbo SE is referenced hereinafter as MDT.
 COST SAVING COST SAVING

Fuel Oil Drain Modifications, 4-STROKE ENGINES LUBE OIL QUALITY CONTROL MODIFICATION, 4-STROKE ENGINES

Introduction Benefits Introduction Benefits

There are two kinds of drains in these STX built MDT diesel
engines. These drains can be classified into clean oil and
dirty oil.
• Clean oil : from cylinder head, buffer piston & safety jacket
• Dirty Oil : from fuel injection pump
After applying this retrofit, our customers can re-use the
clean oil and realize reduced waste and increased cost
savings through the modification of the fuel oil drain line on
For example, for a six (6) 16V32/40 STX built MDT engine
configuration on board an offshore drilling vessel, let us
estimate that the fuel oil leakage is approx. 0.7 liter/hour per
cylinder. Assume that the engines are running continuously.
For calculation purposes, assume that the fuel oil is MGO.
Estimated Savings:
• Drain per engine : 11.2 liter/h
• Drain per ship : 67.2 liter/h
During regular operation of 4-stroke engines, the lubricating
oil can be contaminated by micro impurities. Burning heavy
fuel can add to the contamination by increasing the carbon
residues and other foreign matters introduced into the
lubricating oil. For some engines, experience has proven
that centrifuging is the most effective method for cleaning
the engine's lubricating oil. STX has released a Centrifugal
Bypass Lube Oil Filter Solution for select 4-stroke engines in
our manufacturing portfolio.
The Centrifugal Filter Solution has proven itself as being a
key element in reducing component wear while improving
the oil and engine life-cycle. The Centrifugal Filter Solution
provides a low maintenance and environmentally friendly
solution throughout the life span of the engines.
• Centrifugal oil filter processes approximately 10% of the
oil flow provided by the engine pump before returning it
directly to the engine sump.

the engines. • Drain per ship and year : 1.6 m3/day • The particles extracted by centrifugal force are removed
• Drain per ship and year : 588.7 m3/year based on their relative density therefore the size of the
Original:
Dirty
contaminant does not impact the removal.
Fuel + lube oil Water+ LO + FO
Pure
Pure fuel (mixing oil) (dirty drain) Conclusion: the fuel consumption is improved. A positive
Main Generator Engine (V32/40) impact for the environment is lower waste, due to the

FO high press. Pipe Cylinder Buffer Fuel inj. Crankcase reduced amount of sludge oil.
(safety jacket) head piston Pump (Heat box)

Leakage alarm tank

Conn.
Conn. 5284 Conn. 5294 9184/9187

BILGE TANK or SLUDGE TANK (Dirty oil : cannot re-used)

New:
Dirty Fuel + lube oil Water+ LO + FO
Pure fuel
Pure (mixing oil) (dirty drain)

Main Generator Engine (V32/40)

FO high press. Pipe Cylinder Buffer Fuel inj. Crankcase

(safety jacket) head piston Pump (Heat box)

Leakage alarm tank

Conn.
Conn. 5284 9184/9187

OVERFLOW TANK BILGE TANK or SLUDGE TANK

(Pure Oil) (Dirty Oil : Cannot re-use)

Fuel oil service tank

Transfer pump

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 COST SAVING ENVIRONMENT

ALPHA LUBRICATOR* RETROFIT, 2-STROKE ENGINES MDO/MGO OPERATION MODIFICATION

(INCLUDING OPTIONS FOR SLOW-STEAMING)
Introduction
The MDT 2-stroke engine designers have released a cylinder
oil feed-rate optimizing solution which is also available
through the STX group for STX built engines. the new
cylinder oil feed rate depends on:
• The sulphur content in the fuel oil
• The engine load (relative to the amount of fuel injected)
This combination allows us to set an optimal cylinder oil
dosage.
Introduction Benefits
Benefits With the implementation of the EU-Directive 2005/33EC, The advantage of installing the cooler just before the
The Alpha Lubricator Retrofit offers the below advantages: which is aimed at improving the environment in and around engine/generator is that optimal regulation of the fuel
European harbors, the ships berthing in EU harbors are viscosity is then possible at the engine/generator inlet.
• S ignificant savings on cylinder oil with optimized
required to operate on distillate fuels with a sulphur content
utilization of the oil For the lowest viscosity distillates, this may not be sufficient
of less than 0.1%. This solution is introduced to cool the
• Lower particle emissions levels for cooling the fuel since the cooling water system on board
MDO/MGO, and can be installed after the circulating pumps
• Reduced combustion chamber wear typically averages 36°C as LT cooling water.
as shown in the picture below.
• High pressure injection directly into the piston ring pack
In these cases, we recommend installing a so-called ‘chiller
• Injection timing & feed rate control
unit’.
• Pre-lubrication of the cylinder before starting the engine

Technical Details

Description Mechanical Alpha Lubricator*

0.9 g / bhp.h(K/L) S% x 0.25 g/bhp.h

Feed Rate
1.1 g / bhp.h(S) (Standard : 0.75 g/bhp.h)

Oil Consumption RPM dependent LOAD dependent

Pump Stroke Injection Frequency

Adjustment of Feed rate
(Adjusting Bolt) (in HMI)

Pump stroke Adjustable Fixed

1/1 revolution
Injection Frequency Adjustable
(fixed)

Injection Pressure 4-5 bar 40-50 bar

Chiller unit Fuel Temperature vs Viscosity

Oil Actuating Power Camshaft rotation Booster oil pressure

Operating Method Mechanic Electronic

* ALPHA LUBRICATOR design property of MAN Diesel & Turbo SE

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 ENVIRONMENT ENVIRONMENT

BALLAST WATER MANAGEMENT SYSTEM (BWMS) NOx/SOx REGULATION (TIER II & TIER III) MODIFICATION

Introduction Benefits Introduction TIER III solution

STX Marine Service offers a unique yet comprehensive BWMS Marine diesel engine makers reduce the NOx emissions + SCR (Selective Catalytic Reduction)
• Each fleet or even individual vessels within the fleet may The Selective Catalytic Reduction System (SCR) effectively
turn-key solution by providing technical support, a feasibility mostly by applying low NOx fuel nozzle, applying injection
require varying BWMS solutions reduces NOx in low exhaust gas temperature conditions.
study, the engineering, procurement, project management, timing delays and increasing the charge air pressure.
• Minimal amount of modifications to the physical vessel
installation, and commissioning of the selected Ballast However, it has become necessary to develop more efficient
condition 6S46MC-C 25%LOAD 50%LOAD 75%LOAD 100%LOAD CYCLE
Water Management System. As well, our global after-sales technologies (EGR, SCR, etc.) to reduce NOx emissions TIER I 18.1g/kwh 17.2g/kwh 14.7g/kwh 12.4g/kwh 15.8g/kwh
• Advanced preparation: modular prefabricated design
service network is available 24/7 for ensuring operational in order to prepare for the further reinforcement of the TIER III 2.9g/kwh 3.1g/kwh 2.9g/kwh 2.5g/kwh 2.8g/kwh
• Shortened installation period with most current
satisfaction. The selection of an appropriate ballast water regulatory limits. Tier III is achieved with pre-turbine SCR
technologies
management system is a complex process because no
• Comprehensive service support network Benefits
single BWMS application universally solves every maritime
TIER II solution Vaporizer &
mixer unit
operator’s needs. Each fleet has diverse needs in terms of the
• Higher charge air pressure ratio SCR reactor
Control panel
technical requirements based on a vessel’s unique physical
• Increased compression ratio Air compressor
& air tanks

and operational conditions. Regulatory requirements must • Retarded injection timing

also be met. STX is exceptionally experienced in the field of • Variable Injection Timing
retrofitting services which includes customized support for
Urea solution tanks Urea supply unit
the ballasting solutions.

+ EGR (Exhaust Gas Recirculation Solution)

BEFORE AFTER The EGR recirculates part of the engine’s exhaust gas
back into the cylinders resulting with lower combustion
temperatures. Because NOx forms primarily when a mixture
of nitrogen and oxygen is subjected to a high temperature,
the lower combustion chamber temperature introduced
though the EGR reduces the amount of NOx.

- Filter shall be installed on E/R 2nd deck

- Main ballast line shall be modified
- Stripping eductor line shall be modified
- After modification, A/P(after peak) tank can be filled with ballast water by
No.2 ballast pump

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 SAFETY SAFETY

CHARGE AIR SHUT-OFF DEVICE
INSTALLATION, 4- STROKE ENGINES
Introduction
Designed for select applications, the Shut-off Flap Valve will
ensure the necessary shut-down of the engine in hazardous
conditions by blocking air flow which may also include
combustible gases and vapors.
Benefits
The spring operated air shut-off device mounted in the
air intake system prohibits air flow from entering into the
engines and cylinders. This allows us to protect personnel
and equipment from unexpected incidents. The system
can be manually or automatically controlled responding to
variety of hazardous elements.
SPLASH OIL MONITORING SYSTEM,
4- STROKE ENGINES
Introduction
The Splash Oil Monitoring System is an innovative solution
which can prevent the engine from major damage by
detecting an increase in the crank-case oil temperature.
Benefits
In the event of even a slight increase in the localized oil
temperature, which may be caused by bearing damage
or corrosion, the Splash Oil Monitoring System stops the
engine immediately to protect it.
BEARING WEAR-DOWN MONITORING SYSTEM, 4- STROKE ENGINES
Introduction
Recently as ship builders and ship owners have found more
value in the means of preventing internal engine damages,
demand for condition monitoring systems has also risen. To
meet the growing expectations of engine monitoring, STX
has introduced our Bearing Wear-Down Monitoring system
for 2-Stroke diesel engines with cylinder bores larger than
460mm.
This monitoring system assists through early detection of
abnormal wear-down of bearing parts, thereby helping to
prevent failures. System structure (example)
Benefits
Real-time bearing wear monitoring, supports by predicting
failures thereby reducing the risk of unexpected costs.

• Accurate wear sensing - maximizes uptime

• Water In Oil(WIO) sensor can be applied as an option
• Long term data recording and reporting
• Automatic calibration - easy, low cost set-up

System structure (example)

Open state
System structure (Dr. E Horn)

Close state

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 TROUBLESHOOTING TROUBLESHOOTING
& MAINTENANCE & MAINTENANCE
MECHANICAL & ELECTRICAL TROUBLESHOOTING CRANKSHAFT RECOVERY (POLISHING & IN-SITU)

Introduction Introduction
Preventing eventual failures or managing after experiencing As contaminants may in some instances be introduced into
a failures in the engine room, STX offers qualified and the Lube Oil, ridge wear or crank pin journal ovality may Working Procedure
experienced engineering for troubleshooting mechanical rapidly develop on the crankshaft.
and electrical failures through:
STX Marine Service provides expert in-situ Crankshaft
• Investigating the root cause Polishing Services through our highly skilled and specialized
• Offering the solution technicians.
• Repairing and restoring
• Prevention of repeated failures

Application Die spotting with test shell

Typical(preferred) contact pattern
Die spotting with test shell
Not acceptable contact pattern
Contact area = 80% Contact area < 65%

■ Mechanical & Electrical Systems

• Engines, Turbochargers, Governors, Alternators, Local

Control Panels, Maneuvering Systems, Aux. Equipment etc.

■ Hull Systems & Control Programs

• Fuel oil system

• Lube oil system
• Cooling water system
Die spotting with test shell Die spotting with test shell
• Starting air & Control air system Typical(preferred) contact pattern Not admissible
Contact area = 80% Concavity and single non-contact
• Combustion air system area > 10%

• Pneumatic system

Benefit
STX Marine Service provides quality services for marine and
offshore installations. A great variety of technical skills and
experience acquired through our various business areas
within the STX group are available globally, at competitive
rates.

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 TROUBLESHOOTING
& MAINTENANCE
Maintenance Exchange Program
Introduction
Quality, economical feasibility and reliability are always
priorities for our customers – whether they specialize in the
offshore industry or operate cargo vessels internationally.
STX helps owners to manage their diesel engine planned
maintenance through our competent field and workshop
services. With key jobs being handled in STX’s professional
workshops, and STX crews attending on board, quality,
safety, time and cost management remain at the forefront.
Modifications to new containers for easy loading and unloading
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TROUBLESHOOTING
& MAINTENANCE
Benefits
Our Maintenance Exchange Program for overhauls can be
customized for each customer’s operating needs and helps
by reducing the maintenance down-time of the engine.
An overhaul with the exchange program can take 30% -
50% less time than performing the planned maintenance
without it – and the competence of our personnel helps to
ensure the long term reliability of the engine.
This means: improved risk management for your fleet and
peace of mind for your crews on board.
Customized transport and storage solutions
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 UPGRADE UPGRADE

PlC MoDIFICATIon L16/24 MK2 VERSION-UP

Introduction Benefits of the New PLC model Introduction

STX's engine factories often manufactured 4-stroke gen- Through our experience, we have noted some sticking inlet & exhaust valves in select 4-stroke engine applications. In some
• Improved reliability
sets with ABB CS31 and AC1131 control and safety system cases, the piston crown has even been in direct contact with an opened sticking valve, resulting in serious damages. To minimize
• Reduced overall operating costs
PLCs. Since approximately the end of 2007, these PLCs are the risk of sticking valves STX has introduced a new design specification for STX built MDT 5L~9L 16/24 engines.
• Easier to maintain
no longer produced and we have been unable to offer
• Approximately a 40% more compact design
after-sales support for them. Problem Estimate Reason
• Integrated project concept for easy handling
1 Fuel Oil Pump plunger & barrel sticking Carbon contamination
As some vessel operators are interested in replacing the
Ignition quality low
2 Exhaust & intake valve sticking
older control systems with current solution for continuing Please contact your nearest STX service center for support Carbon contamination
and improving safety and reliability, the STX group is in upgrading the controls for any of your STX built engines. 3 Exhaust gas temp’ high Combustion quality low
OLD VERSION NEW VERSION
pleased to offer retrofit solutions for the engine controls. (Average 100°C above) Fuel valve damage
Carbon contamination
4 Valve bridge damage
In addition to the new hardware, we also include the most Clearance misadjustment
Reduced camshaft / valve lift
up-to-date monitoring system softwares. 5 Turbo charger (NR12/S) damage Carbon contamination
(Turbine Rotor break) L.O quality low
Combustion condition low
6 Lube oil quality low
Blow-by

Engines running with relatively high viscosity fuel incur poor atomization and high
OLD NEW
carbon residue. This is a primary cause of valves sticking on L16/24s (1,200 RPM) engine.
OLD ABB PLC
Benefits
In order to support customers, STX proposes an upgrade for existing engines:

Introduced countermeasures:
■ Improved turbochargers
■ Pre-heating valve

New design changes:

NEW PLC
■ New Rotocap
■ New valve springs
■ New valve guides
■ Valve pockets in piston
■ Reduced camshaft-/ valve lift

14 15
 UPGRADE UPGRADE

FUEL OIL QUALITY CONTROL UNIT(FQCU), 4-STROKE ENGINES

Introduction Purpose of this development Case Study: Viscosity control unit specification
Damage on cylinder heads and valves have been reported, The Fuel Viscosity Control System is a technique to control
which sometimes also leads to damage on pistons and viscosity and temperature of fuel oil (HFO) for more efficient • Plate type electric heater
HULL/YEAR 2010 2011 TOTAL EVENT
turbocharger components. STX has investigated the causes combustion in motor vessel diesel engines and oil-fired • Viscosity controller
in close cooperation with a reputable shipping company for power plant generators. • Viscosity abnormal alarm
PAN EAXXX 29 9 38
one year and reached the below conclusions:. • Fuel oil filter differential press high alarm
The viscosity of the fuel oil greatly depends on the
PAN FOXXX 24 10 34 • Flexible hose for external connection
• Proper fuel oil and lube oil treatment is essential for temperature: the higher is the temperature the lower is the
• Temperature sensor & pressure gauge
preventing valve sticking viscosity. For optimal combustion, the viscosity of the fuel
• Fuel oil duplex filter
• The viscosity of HFO (380cSt) should be kept at 12~18 cSt should be in the range of 12-18 cSt. To maintain this value,
(Option : manual / auto back flushing type)
after the pre-heater but 10~15 cSt at the engine inlet. a combination of a viscometer, PID controller and heat is 30
• Filter mesh (Option : Abs. 10 / 25 micron)
• A well maintained lube oil system is also important. applied. The viscometer measures the actual viscosity of
• Fuel oil duplex filters often installed on ships does not the fuel, this value is compared with the set point in the 20
satisfy the STX - MDT specifications (MDT service letter controller and the command is sent to the heater to adjust
(SL2013-577) design spec : 50μm → 25 μm). the temperature of the fuel 10

0
2010 2011
Viscosity Control unit

solution module is installed by stx

engineer at G/E Fuel oil inlet common line

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 UPGRADE UPGRADE

NR CONTAINMENT UPGRADE
(FOR PREVIOUS GENERATION NR & NA TYPE TURBOCHARGERS)

Introduction Service package

STX offers the containment upgrade for previous generation Ductile casings STX Marine Service provides high quality service for your turbochargers including application of the NR upgrades.
NR & NA type turbochargers. For the convenience of the equipment owner, we recommend a variety of service packages:

The designer of the STX built NR and NA type turbochargers,

MAN Diesel & Turbo ("MDT"), has changed the turbocharger Strengthened Concept. 4
flange
casing material design to a ‘Nodular Cast Iron’ for previous
connection Concept. 3
generation turbochargers which were originally designed between
and manufactured with grey cast iron casings. This includes bearing Concept. 2
casing and
the following turbocharger types: “NR12, NR15, NR17, NR20, compressor
NR24, NR26, NR29, NR34, NA34, NA40, NA48, NA57, NA70”. casing Concept. 1
Recently, MDT has finalized the ‘Nodular Cast Iron’ design
Containment safe design
concept for the new components.
• Prepare to • Change work • Interval • None
consumption parts for upgrade maintenance (Turn-key
STX Marine Service and our global network companies Costumer • Changed work • Interval from STX)
supply the materials and services for upgrading these STX Scope • Interval maintenance maintenance

built MDT turbochargers through close cooperation with

new
our sister company, the original turbocharger manufacturer,
STX Heavy Industries.
NR Containment Certificate

• Concept 1: STX supplies upgrade components

• Concept 2: STX supplies upgrade components plus the relevant interval overhaul parts
previous • Concept 3 : STX supplies upgrade components and the installation service
• Concept 4 : STX supplies the upgrade components and installation plus the maintenance
interval OH parts and service (12K, 24K Turbocharger TBO)
compressor casing turbine outlet casing

turbine intake casing

bearing casing

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 EFFICIENCY EFFICIENCY
& PROFICIENCY & PROFICIENCY
E-MAS(Engine Monitoring & Analysis System) WORKSHOP TRAINING

Introduction Website and Mobile Application Introduction Benefits

STX's E-MAS solution offers remote engine performance The practical training on 2 & 4-stroke engines in STX's The trainees will understand the engine system and design
• No constraints in time and location for engine condition
monitoring and on-line analysis of the trends, while workshop will enable the trainees to operate the engine features of all type engines manufactured within STX
monitoring through our website and mobile application
providing the customer peace of mind to implement an systems as safely, reliably and most economically as possible. through these courses.
• Research of daily & monthly reports of engine experts
optimized maintenance program.
• All necessary information including engine manuals and • Customized training course • MDT
Benefits latest service reports available at your fingertips • Workshop training course • NIIGATA
E-MAS analyzes engine operation data and provides the • CUMMINS
customers with comprehensive information.
• Introduction of 2 & 4 stroke engine
• Engine Basic Information • Main Components
• Engine Condition • Control Systems
• Expected Maintenance Timing • Emergency Operation
• Warning for Accidents
• Fuel Oil Consumption
• Average Engine Load
• Performance Curve

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 Global Network
Global Network
U.S.A
Brazil
STX Maine Service Co., Ltd
Brasil Service Center
(For Power Plant Services)
B.Y. Jung
Alameda Santos, 1357,
10F Sao Paulo, SP,
01419-908, Brasil
musma2183@onestx.com
stx-service-br@onestx.com
STX Serivce Europe B.V.
Netherlands [Rotterdam]
J. G. Gim
Sheffieldstraat 7 3047 AN
Rotterdam, Netherlands
Tel : + 31-88-451-2001
gimjonggun@onestx.com
stx-service-europe@onestx.com
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STX Maine Service Co., Ltd
Korea Head Quarter
Y.S Cho
3F PANOCEAN Bldg., 102, Jungang-Daero,
Europe Jung-Gu, Busan, 600-725, Korea
■ Netherland
■ Greece Tel : + 82-51-461-5431
■ Germany yscho@onestx.com
stx-service-hq@onestx.com
Korea
(HQ)
Iraq
China STX Maine Service Co., Ltd
Iraq Office
(For Power Plant Services)
Phillippines K.S Cho
House 25, Street 34, Locality 923, Hay Babel,
Singapore Jadiriyah, the region
presidential, BAGHDAD, IRAQ
Tel : + 82-070-8245-1606
shpark21@onestx.com
STX Service Americas, LLC
Michele Laughlin-Payne
4750 Windfern Houston, Texas 77041
Tel : + 1-173-934-0056
mlpayne@onestx.com
stx-service-usa@onestx.com
STX Maine Service Co., Ltd
Philippine Branch
(For Power Plant Services)
J.Y. Son
1406, The Trade & Financial STX Service Singapore Pte.,Ltd.
Tower, 7th Avenue, Corner
32nd Street, Fort Bonifacio, Jason Han
lobal City, Taguig, Philippines No19 Joo Koon Road Singapore 628978
Tel : + 63-2-625-4314 Tel : + 65-6898-2378
jyson@onestx.com jshan@onestx.com
stx-servicesg@onestx.com
Germany [Hamburg] Greece [Athens]
S.J. Choi stx-service-europe@onestx.com STX Maine Service Co., Ltd
#648, 6th Floor(Regus), China Service Center
Millerntorplatz 1, S.Y. Bae
20359 Hamburg, Germany 2002, West Building, Zhongrong Hengrui
Tel : + 49-40-80909-2172 tower #560 Zhangyang Rd. Shanghai, China
soonjoonchoi@onestx.com Tel : + 82-70-7931-4200
sybae@onestx.com
stx-service-cn@onestx.com
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