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ME307
Countermeasures for Insufficient Heating of Main Fuel Oil Heater
Technical committee

Ship type Tanker

Date of build June 1975, Ishikawajima-Harima Heavy Industries Co., Ltd. Kure Factory
Navigation route Japan ~ Persian Gulf
Trouble machinery
Category Auxiliary machinery/heat exchanger
Name Main engine fuel oil heater
Type
Maker
Date of trouble 1985~1995
For over the past 20 years, shipping companies have suffered from low quality ship fuel oil and are
grappling for possible countermeasures. There are three major characteristics observed with low quality
oil that have especially raised problems in recent years.
One characteristic is represented by poor storage stability, poor mixing stability, and production of large
volume of wet sludge. Another characteristic is represented by oil with large amounts of sediment
(sludge) contained from the time of loading.
The final characteristic is represented by much asphaltene and paraffin contained which significantly
reduces the heat exchange efficiency of a fuel oil heater.
The failure of this case is related with deficiency of the main fuel oil heater which was caused by fuel oil
containing some of these low quality ingredients. This report describes how the crew members of this
vessel and engineers concerned worked on preventive measures over long years and solved the problem
through adoption of a spiral coil type heater.

1. Outline of breakdown

The main boiler fuel oil line was severely contaminated on the main fuel heater oil side and the optimal
set temperature of 120~125ºC could not be maintained. This led to insufficient combustion, contami-
nation, etc. of the main boiler.

2. Repair

The preventive measures which have taken for approximately the past 7 years and their effects are
mentioned in chronological order as follows:
1) The heater element was pulled out and cleaned. (Around 1987~1990)
Every time the vessel returned to a Japanese port, heater elements of 1 or 2 heaters were pulled out
and cleaned.
Even with cleaning, they became contaminated again in a short period.
2) While the heater remained cool, various solvents mentioned below were charged into the oil side
and circulation cleaning was performed:
(1) Light oil or white kerosene (Around 1987)
Surface of sludge adhered to the heater elements would just soften but exhibited no effect.
(2) Carbon remover (A) (Around 1990)
Although some cleaning effect was achieved, its use was suspended due to generation of toxic
gas.

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 (3) Carbon remover (B) (Around 1993)
As in the case of (2), cleaning effect was observed. However, as toxic gas occurred at above
40ºC and there was corrosion effect on copper or aluminum pins constituting the heater ele-
ments, its use was suspended.
(4) Carbon solvent (P) (Around 1993~1995)
The cleaning effect was most outstanding and its use eliminated pull-out work for washing the
heater elements.
Although a slight irritating odor was emitted, handling was easy. However, use of safety glasses
and rubber gloves etc. is essential.
3) Replacement of 2 units with aluminum pin type fuel heater assembly (Around 1993~1994)
Replacement with aluminum pin heater assemblies were carried out, as catalyst effect of the copper
pins for the heater element tended to induce adherence of sludge, the heat transfer area was reduced
by abrasion of the copper pins, etc.
No outstanding effect was observed.
4) Supply of combustion accelerating type corrosion-proof additive (T) into fuel tank (Around 1995)
The additive was expected to prevent occurrence of sludge in a fuel tank, to prevent contamination
of a fuel oil heater, and to prevent boiler contamination. Out of use for about 7 months while various
data were taken, no noticeable effect was obtained. In addition, because of high cost, its use was
suspended.
5) The conventional fuel oil heater using 3 units in parallel was altered in piping into series use to
improve heat exchange efficiency. (Around 1995) It was discontinued in the planning process.
6) Replacement of 1 unit with spiral coil type fuel heater assembly (1996)
This is outstanding as a fuel oil heater and is free of damage/clogging by contaminant. Further, as
high heat exchange efficiency is ensured, continuous operation is now performed using this single
heater. The other 2 heaters are maintained as stand-by units and are out of service at the moment.

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Fig. 1 Main fuel supply piping diagram

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 Fig. 2 Spiral coil type heat exchanger

Structure

This heat exchanger consists of a shell and heating element serving as the heat transmission surface
formed into coil.
Shell ----- A flange is welded to one end of the shell and an end plate to the other. Both ends of the shell
have outlets/inlets for fuel oil. Further, the shell is mounted with sockets for a relief valve, pressure
gauge, air bleeding valve, and drain valve.
Heating element ----- The heat transmission surface consists of narrow diameter seamless carbon steel
pipes or stainless steel pipes forming a group of coils in spiral form. The coil group consists of left spiral
coils and right spiral coils stacked alternately in sequence. Each coil is made of a single steel tube with
no welded connection. The both ends of the element have are welded to the pipe plates of the assembly
chamber and the distribution chamber. The optimal number of coils of each layer is determined ac-
cording to capacity. The elements are wound around a center pipe where the fuel oil will flow through.
The inlet of the center pipe is attached with a flange to connect with an external line. The element is free
to expand/contract by heat, and is designed so that it can easily be pulled out for inspection/cleaning.

Features

- It enables flexible design to allow for maximum heat transmission efficiency.

The optimal heat exchanger can be designed by varying the number of coil layers, the number of rows,
and pitch.
- Compact and light weight
As heat transmission area per unit length is large, it is compact and light in weight.

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- Self-cleaning function
As the fuel oil becomes turbulent when it passes through the cross-wound pipe group, the heat trans-
mission surface is self cleaned. Therefore, it can ensure highly efficient long-term operation free of
clogging with oil sludge, etc.
- Less effected by thermal stress
The heating element is supported at one side by the shell via a flange, while the other side of the heating
element is free to expand and contract.
- Free mounting
It can be mounted either horizontally or vertically.
- Easy maintenance/inspection
For maintenance/inspection, the main flange can be removed and the heating element can easily be
pulled out.