INSIDE Special Marine - KRAL AG

INSIDE
September 2006
SPECIAL
Special Issue for the Marine.

content
KRAL as a partner for unique solutions
SUCCESS DEMANDS CONTINUITY 03
KRAL AG FOR MARINE APPLICATIONS 04
THE OIL PRICE STORY 06
KRAL PUMPS IN PRACTICAL MARINE APPLICATIONS 10
PUMP UPGRADE FOR THE MARINE 12
OUR PartnerS in THE marine
PG MARINE GROUP 14
Real Partnership Brings Global Customer Benefit.
ROLLS-ROYCE 16
A World Leader in Marine Solutions.
E.R. SCHIFFAHRT 18
Upgrading to KRAL Pumps With Magnetic Coupling.
WESTFALIA SEPARATOR 20
Hot Stuff.
KUPKE + WOLF 22
A Long Service Life Despite Cat Fines.
MTU FRIEDRICHSHAFEN 24
Fuel Consumption Measurement in Harsh Operating Conditions.
CATERPILLAR 26
World Class Diesel Engines.
AALBORG INDUSTRIES 28
World Leading Brand in Marine Boilers.
JAN LOKKER & ZONEN 30
Higher Profits Despite the Constant Increase in Fuel Prices.
MOTOR YACHT „LARA“ 32
Efficient Performance With the KRAL Consumption Measurement System.
special

editorial
Success demands continuity
and concentration.
Dear readers
Stiff competition forces you to
be fast and flexible as well as
innovative and reliable in your
dealings with your customers.
You also expect these qualities
from your shipbuilding partners
and system providers.
We at KRAL not only take these
expectations very seriously, we
have also adjusted our thinking
and our actions to take them
into account. As it is proven by
the steadily increasing number
of ship owners, shipyards and
manufacturers of booster modules,
diesel engines, transmissions
and winches who believe
in us.
KRAL has proven that with
innovative solutions, it is possible
to have greater on-board
safety and still reduce operating
costs. With our first KRAL
INSIDE SPECIAL, Special Issue
for the Marine, we want to present
various solutions that have
proved to be highly beneficial.
Also included are reports from
KRAL customers, which document
the powerful presence of
KRAL in marine engineering.
The innovative solutions are
the result of development with
a practical emphasis. Our customers’
requirements are not
simply taken into account; they
form the basis for tailor-made
development results. You will
benefit from our know-how
both when building new ships
and when modernizing existing
ones.
Fritz Huber
CEO
special

Introduction
KRAL AG for marine applications.
There is something romantic about life at sea which people still find fascinating. But in complete
contrast, the commercial maritime business is subject to uncompromising demands. These
include making journey times as short as possible and the increased costs of fuel, maintenance,
service and personnel. So in shipbuilding, it is correspondingly important to have reliable
partners who take these problems into account and provide solutions and services to give you a
crucial edge.
Our marine customers are internationally
active organizations
and groups, which need
capable and efficient partners.
There is currently a boom in
modern navigation and shipbuilding,
which means that we are
facing some demanding tasks.
Shipyards, ship owners, module
and winch makers, as well
as the manufacturers of diesel
engines and marine boilers dominate
activities at KRAL with
60% of the business volume.
It is not our aim to make business
out of replacement parts.
We want satisfied customers
and are looking to the future.
Many ships are modernized
with our know-how. Many ship
owners have also chosen KRAL
for their new ships. The pump
upgrade project (page 12) and
retrofitting with modern fuel
consumption measurement systems
are two of the successful
examples. The manufacture
of pumps and flowmeters for
marine applications makes our
company unique, and a consi-
stently pursued growth strategy
raises our profile and makes
us better-known.
Scope of supply for marine
applications.
KRAL supplies fuel pumps, hydraulic
pumps and lubricating oil
pumps for marine applications,
as well as complete measurement
systems for diesel engine
fuel consumption.
With our highly specialized
partner, the PG Marine Group,
we supply the smaller offshore
supply ships, coastal tankers
and drillships. E.R. Schiffahrt
is one of our typical customers
who equip their container ships,
even up to the Post-Panamax
size, with magnetically coupled
KRAL pumps. Rolls-Royce gets
the pumps for its anchor and
deck winches from KRAL. In
Germany, we are the market
leader for supplying circulation
and booster pumps to leading
booster module manufacturers
such as Kupke+Wolf and Westfalia.
Strategy.
If you want to be successful,
you need a strategy. The stringent
demands of marine applications
require knowledge to
be focussed and continuously
extended. This is why we develop
and produce our high-quality
products at our company
headquarters in Lustenau - Austria.
We keep ourselves and our
partners fit to face future challenges
in ongoing internal and
external training sessions.
We provide an attractive standard
program of products for
marine applications.
Our product designs are optimized
with regard to cost,
have a long service life and a
high power density. We use
high-quality norm materials and
standardized components.
We personally demand perfect
quality from our solutions and
services, which makes KRAL
your ideal partner for marine
applications. We are on the list
of suppliers for leading ship
owners and shipyards, which is
why we are often the original
fitters.
We help reduce costs for marine
applications.
Our hermetically sealed, magnetically
coupled booster module
pumps vastly reduce life
cycle costs compared to the
conventional, mechanically
sealed pumps that were formerly
used. Our fuel consumption
measurement system can save
so much fuel within short time
that the system pays for itself in
less than a year. The cost pressure
caused by rising fuel prices
calls for solutions that reduce
special

consumption, thus minimizing
the effect of the dramatic rise in
the price of oil. Fuel consumption
can be recorded with the utmost
accuracy, thanks to KRAL’s
twenty years of experience as
a flow measurement specialist.
Measurement results need to
be precise as they determine
the action to be taken to save
expensive fuel.
We target our innovations
to the areas where they are
needed.
We have an eye for innovation,
and at our test- and calibration
rigs, we also run basic research.
However, the input for the developments
mostly comes
from intensive investigations
run jointly with our customers.
We maintain a lively exchange
of ideas with ship owners, shipyards,
system suppliers, classification
societies and universities,
to meet the continuously
increasing demands and needs
of our customers.
We do not think of ourselves as
service engineers, who repair
their products. We are installation
analysts, taking a holistic
approach to our customers’
installations to cover both operating
and environmental conditions.
This enables us to make
improvements exactly where
our customers have previously
had to accept restrictions. Our
tailor-made solutions are the
outcome of this collaboration.
It is often the small improvements
that were difficult to
analyze which now ensure that
operation is far more reliable.
Our customers honor our innovative
strength. They appreciate
our help and keep us informed
about future projects. In this
way, we are often the original
fitter.
We are a reliable partner for
our customers.
KRAL AG has been working in
the pump business for almost
sixty years. The company will
also remain in private ownership
in the future, in the third
generation. The positive attributes
of an owner-managed
company are strong identification
with its products, its services
and its values. This is how
we keep our independence.
This continuity creates security
and belief. These are the advantages
for our customers and for
our workforce. Our response to
customer requests is fast and
unbureaucratic.
We keep in close contact with
our customers in the global
market.
As the business segments in
which we are active rate highly
on the international stage, a
global presence is required.
Our group headquarters is in
Lustenau - Austria. In the USA
we have our KRAL - USA subsidiary
in Matthews, NC., and
sales office in the Chicago
area. Germany has three sales
offices, and we also have 47
partners representing us worldwide.
This is how we make sure
that advice, service and development
projects can be quickly
implemented.
Safety on board ship is important
to us.
Maximum safety is a highly significant
issue at sea. This must
be viewed from the economic
viewpoint, as well as with regard
to the safety of the people
on board ship. For KRAL, the
particular challenge here is to
maximize safety on board ship
with needs-based solutions,
such as a magnetically coupled
pump. Leading KRAL technology
ensures greater on-board
safety and the reduction of the
fire risk is in keeping with the
IMO’s SOLAS (Safety Of Life At
Sea) Convention.
Fritz Huber
CEO
SPECIAL

MARket
From two to more than 70 dollars –
the oil price story.
The age of low-cost energy is definitely over.
For a long time it was not even possible to imagine the current oil price level. With fuel consumption
measurement, KRAL gives customers the opportunity to save fuel.
Everything was stable in the
world of the oil market until
the start of the seventies. Fuel
was readily available and cheap.
Then suddenly, OPEC, the Organization
of Petroleum Exporting
Countries, tightened the
reins. In October 1973, OPEC
cut production and started nationalizing
the oil infrastructure.
This was triggered by the conflict
between Israel and the
Arab countries during the fourth
Middle East war. The first great
oil crisis in history had arrived.
The price of oil quadrupled. The
oil price stayed at this far higher
level until the end of the seventies.
From then on, it was one
thing after another. The Shah
was toppled in Iran, and western
oil companies were forced
out of the country.
40-dollar mark broken for the
first time.
In the early eighties, the oil price
was already 40 dollars a barrel. In
subsequent years, OPEC again
increased its production quotas.
There was now more North Sea
oil on the market. Europeans
had responded to the first oil crisis
in the seventies by searching
more industriously for their own
sources of oil, to become more
independent of OPEC oil. At the
end of the eighties, oil was once
again costing less than 20 dollars.
At this time the Iraqi dictator,
Saddam Hussein, converged
on the neighboring country of
Kuwait. America liberated the
tiny Gulf State in its “Operation
Desert Storm”. Oil prices,
which had greatly increased during
this crisis, fell dramatically.
The trend in oil prices was unspectacular
until 1997, when
OPEC increased production quotas
again. This increase in supply
however encountered rapidly
falling demand, owing to the
economic crisis in Asia. Also,
due to the unusually warm win-
special

MARKet
ter, stocks had grown considerably.
As a result, the oil price fell
to ten dollars.
Historic low at the end of the
nineties.
Optimists were already envisioning
oil prices of a mere 5
dollars. OPEC‘s deft response
was to reduce production quotas.
To the amazement of many
experts, the federation remained
consistent and kept to the given
quotas. Within two years,
the oil price had tripled, until US
President Bill Clinton released
oil onto the market from the
country‘s Strategic Petroleum
Reserve. The recession in the
USA went one step further. The
price of black gold fell to less
than 25 dollars. The price slump
was also intensified by the terrorist
attacks of September 11 in
New York. Many market observers
were envisaging a setback
in economic activity and in the
demand for oil. It was then that
OPEC got its grip back on the
oil market with reduced production.
By the time of the Gulf war
at the start of 2003, which led
to the downfall of Saddam Hussein,
the oil price had risen to
almost 40 dollars. Fortunately,
official military action only lasted
a few weeks, and the infrastructure
was not severely affected.
The price of oil kept on going
down.
Boom in Asia.
However, the fall in prices did
not last long, as there was no
stopping the economic boom in
Asia. The demand for oil in 2004
was rising faster than it had in
the past 20 years. Several times
the IEA, the International Energy
Agency, had to adjust its oil demand
forecasts upward. At the
end of May, the tense supply
situation was made more acute
by the threat to Saudi oil installations
from Islamic terrorists. Although
OPEC wanted to expand
production, fear of terrorism
drove the price in New York to
over 42 dollars. In August 2004,
the oil price kept reaching new
record levels, the last of which
was virtually 49 US dollars. The
50 dollar mark battle began. Various
events, such as the threat
of insolvency hanging over the
Russian Yukos oil group, made
the market ever more volatile.
US-$ / Barrel Annual average.
80
75
70
65
60
55
50
45
40
35
30
25
20
15
10
5
0
1960 1965 1970 1975 1980 1985 1990 1995 2000 2005
SPECIAL

MARKet
No end in sight.
On 28 September 2004, a barrel
of light US oil cost more than
50 dollars for the first time. Hurricane
“Ivan” had had a highly
adverse effect on oil production
in the Gulf of Mexico. As a result,
stocks in the USA declined
sharply. On October 12, the International
Energy Agency again
raised its demand forecast. The
price for US oil rose to over 54
dollars. February 2005: after a
phase of relative peace, the 50
dollar mark was seen again. The
relationship between high demand
and tightly calculated supply
became even more tense. Experts
were further unsettled by
the smoldering conflict over the
Iranian nuclear program. In June
2005, the oil price cleared the
60 dollar mark for the first time.
Worldwide production could
hardly be increased any more.
At the same time, despite the
high prices, demand just kept on
increasing. At the end of August
2005, fear of hurricane Katrina in
the Gulf of Mexico heaved the oil
price in New York to over 70 dollars
for the first time. Following
the adverse effect on oil production
caused by the hurricanes,
many countries released some
of their strategic petroleum reserves.
By the end of 2005, the
oil price had again clearly lost
ground and fell below 60 dollars.
Since the start of the New Year
in 2006, the oil price has again
continued to rise and recorded
its record high in August at 73
dollars per barrel. Responsible
first af all for the steady price
increase is the first for oil of the
growing global economy, especially
the emerging markets of
India and China. Oil producers
can hardly keep up with the rise
in demand, their oil production
facilities are running flat out.
Secondly and currently keeping
the mood tense on the market
over recent months, is the conflict
in the Middle East. Should
the Middle East conflict escalate
and Iran cease to be an oil supplier,
it is perfectly conceivable
that the price could rise to 100
dollars. Whatever happens, the
global demand for oil will remain
heavy throughout 2006 and the
trend of the last 30 years suggests
that no price reduction is
to be expected in the future.
The response to the rise in
oil prices is to save.
The logical consequence of constantly
rising oil and fuel prices
is to find ways to conserve. At
KRAL we have noticed that the
high cost of energy is causing
people to be more conservative
in it’s use. Our customers who
run internal-combustion engines
now have the reduction of fuel
consumption as their goal.
Vast potential savings can easily
be made by cost-conscious
operation of diesel engines and
turbine systems. In order for this
to happen, the operator must be
given the option of a reliable tool.
Section through a KRAL Volumeter.
A consumption measurement system
includes two KRAL Volumeter.
KRAL BEM 500 electronic system for measuring fuel consumption.
special

Photo: Terje S. Knuden/Hydro.
KRAL offers a fuel consumption
measurement system for diesel
engines and turbines operating
on liquid fuel. The ideas for economical
operation often come
from our customers. They know
their systems inside out. They
know where they can make improvements.
Fuel consumption measurement
variations.
The Lokker fishing business in
this issue of KRAL INSIDE is
an impressive example of how
fuel can be saved. Lokker saves
a substantial amount of money
simply by relieving the load on
the diesel engine. This technological
option can be transferred
from a fishing boat to other
ships.
Railway companies also run
energy saving programs. With
electric locomotives, it is easy
to monitor energy consumption
with a current meter. With diesel
locomotives, it is a more demanding
task. The layout of the
fuel system makes it necessary
to measure the diesel fuel both
in the forward and return flow of
the injection pump. The difference
between the forward flow
and the return flow is the volume
of fuel that the engine has used.
Modern diesel engine train units
have an underflow drive. There
is an extremely limited amount
of space available to install additional
measurement systems.
For this application, KRAL provides
a compact measurement
module that contains two KRAL
Volumeter, together with the
sensors.
It is a different situation for
power stations with diesel engines.
About 80% of the operating
costs for installations of this
type are the fuel costs. The economic
efficiency of these power
stations is determined largely by
fuel consumption. This is why
power station operators have
the specific fuel consumption
guaranteed. During the warranty
period, this guaranteed performance
can be monitored using
KRAL fuel consumption measurement
systems.
Engine manufacturers measure
fuel consumption on production
test stands or in the continuous
operation of the installed
engine. On page 26, Caterpillar
describes the need for KRAL
consumption measurement, as
when contracts are concluded,
the consumption specification is
a component part of the contract.
MTU Friedrichshafen GmbH
demonstrates its customer-orientation
on page 24. With the
KRAL fuel consumption measurement
system installed, MTU
offers its customers a measuring
accuracy that cannot be achieved
simply by measuring the level
in the tank. This enables MTU
customers to run their engines
efficiently.
Thomas Flauger
Product Manager
SPECIAL

TECH NEWS
KRAL pumps in practical marine
applications.
KRAL screw pumps with magnetic coupling have crucial advantages for use in fuel supply
systems on board ship. These include lower life cycle costs and significantly higher operational
safety.
With very few exceptions, ships
are run on mineral oil fuels. Socalled
distillates or residual oils
are used, in accordance with
local regulations and availability.
The most economically
significant fuels are diesel and
heavy oil.
Heavy oils cannot be supplied
to the engines straight away.
They must be conditioned in
the ship’s own separators and
fuel modules. These filter out
the solids, separate the water
and adjust the viscosity of the
fuel by heating. For each megawatt
of power, about 5 liters
of fuel flows to the propulsion
engine every minute.
Safe delivery process.
Fuels must be delivered from
the feeding tanks to the service
tanks, forwarded to the separators
and fuel modules and
from there to the fuel injection
pumps of the engines. KRAL
screw pumps are ideal for this
purpose. Because of their high
power density and associated
compact design, screw pumps
offer economic advantages and
are well established in this application.
They are self-priming,
positive displacement pumps,
which can deliver fuel safely
from deeper-lying tanks. Due to
the special principle of positive
displacement with fully continuous
axial displacement of
the liquid, the fuel is delivered
particularly gently and is not
emulsified. This is important,
to assure that any condensation
Tank
K-series pump
C-series pump
Steam generator
DS-series
double
station
Engine
Fuel injection
pump
K-series pump
Mixing tank
K-series pump
Service
tank
Separator
K-series pump
Tank
Boostermodule
Possible uses for KRAL screw pumps on-board ships.
10 special

TECH NEWS
KRAL screw pumps with magnetic coupling.
water contained in the fuel can
be removed in the separators
by centrifuging. The “rigid” characteristic
curves of the pumps,
that is the minimal effect that
changes in viscosity or pressure
have on the delivery rate,
are a further advantage, when
changes in temperature caused
by the climate or the operating
conditions bring about changes
in the viscosity of the fuel.
Improving the availability of
the ship’s propulsion systems.
The properties of the fuels being
used make great demands on
the pumps. Heavy oil, for instance,
is extremely viscous
at ambient temperature, and
despite extensive filtering, abrasive
foreign particles cannot
be totally suppressed.
The benefits of magnetically
coupled pumps.
When a pump fails, the seal is
often the cause. Conventional
shaft seals such as a rotary
shaft lip seal or a mechanical
seal have the disadvantage
that they work with frictional
elements in the sealing gap
and always require functional
leakage.
For some considerable time,
hermetically sealed magnetic
coupling pumps have been
used in the chemical industry
for liquids that must not be
allowed to enter the environment.
Magnetic couplings only
have static sealing elements.
The actual sealing element is
the fixed, built-in can made of
stainless steel. Torque is transmitted
from the engine to the
pump shaft without contact.
The magnetic couplings are
wear-resistant, which increases
the operational safety of the
pump considerably. A further
benefit is that because magnetically
coupled pumps are hermetically
sealed, the pumped
medium does not escape into
the atmosphere and the fuel
module stays clean.
Higher level of safety at lower
costs.
The life cycle costs of a screw
pump with magnetic coupling
are more reasonable than those
of a screw pump with conventional
seal. The magnetically
coupled pump already pays off
within a period of 3 years. In
case of ship failure, the extra
cost of a magnetic coupling is in
no proportion to the daily charter
rate of up to USD 30.000 for
a large container vessel.
Thomas Flauger
Product Manager
The operational safety of the
fuel pumps is crucial for the
availability of the ship’s propulsion
system. The costs associated
with unit failure on board
ship are high.
KRAL screw pumps with magnetic coupling in a fuel module.
SPECIAL
11

TECH NEWS
Pump Upgrade for the Marine.
No more problems with mechanical seals!
As a trial and return project, KRAL has been offering hermetically sealed pumps for boostermodules
to ship owners and operators. These fuel pumps can reduce life cycle costs and increase
engine room safety. At present, every ship owner who has made the test has chosen
to keep the pumps.
Fig. 1: Typical booster module screw pump
with mechanical seal.
Fig. 2: Accumulation of leakage residue in a
pump with mechanical seal.
Defects of screw pumps in marine
booster-modules are some
of the most frequent incidents
affecting life cycle costs and
ship’s availability. Pump designs
with mechanical seals
will always incur a distinct risk
of breakdown. A decisive step
forward in solving this problem is
to avoid the shaft seal. The alternative
technology are hermetically
sealed pumps with magnetic
coupling. Magnetic couplings
overcome the limitations otherwise
common with mechanical
seals in screw pumps. At the
end of the day, the long list of
advantages of using KRAL hermetically
sealed screw pumps
will keep providing the bonuses
of safety as well as low operating
and maintenance costs.
Mechanical seals require
lubrication of the seal faces.
Screw pumps are typically driven
by electric motors. The connection
between the electric
motor and the set of spindles almost
always incorporates a mechanical
seal. Mechanical seals
are widely utilized and have advanced
in technology. Regardless
of their proper usage, mechanical
seals have wearing
parts. To lubricate the seal faces,
manufacturers of mechanical
seals specify a leakage flow.
It is important to note, that a
low amount of leakage – some
ccm/h – is normal and part of a
well engineered design! Fig. 1
shows a screw pump with mechanical
seal. Low volatile liquids
which tend to form solid
residues in contact with ambient
oxygen may accumulate in
the leakage drain. The quality of
the mechanical seal, especially
the material of the sealing faces
and the O-rings are designed according
to the application. Fig.
2 shows a sample where the
motor bracket was nearly completely
filled with coke and carbon
residues after approx. two
years of operation. This accumulation
was caused by the
normal leakage which lubricates
the mechanical seal.
Magnetic coupled pumps are
the solution to mechanical
seal problems.
KRAL screw pumps with mechanical
seal have been improved
for HFO operation in engine
rooms. However, to be on
the very safe side, KRAL has developed
the magnetic coupled
pump as an alternative solution
which completely avoids a mechanical
seal. In screw pumps
with magnetic couplings, the
connection between the electric
motor and the pump shaft is not
a fixed mechanical attachment.
Permanent magnets are fastened
to pump and motor shaft
so that they face one another.
The magnets on the motor shaft
transfer the torque to the magnets
on the pump shaft thereby
rotating the pump spindles. Serving
to seal the pump against the
atmosphere, there is a hermeti-
Cornelius Maersk in the Malacca Strait.
cally tight sealing element – the
containment can – located in the
gap between the opposing magnets.
In Fig. 3 the magnets are
marked red. Once the piping is
connected, the pump is safely
protected inside a perfectly tight
casing. In Fig. 4 you can see the
hermetically sealed pump in the
front, and in the background, the
KRAL pump with attached electric
motor.
Fig. 4: Front: Hermetically sealed pump
casing with can. Back: KRAL screw pump
with motor.
12 special

lindtext
Fig. 3: KRAL screw pump with magnetic coupling. The magnets are marked in red.
Reduced life cycle- and
attractive investment costs.
Spare parts and maintenance
costs of mechanical seals increase
life cycle costs. The use
of high quality mechanical seals
in KRAL screw pumps is the
standard. Even when properly
applied, mechanical seals are
subject to wear. Spare parts and
maintenance costs arise.
KRAL magnetic couplings are
maintenance free. The cost premium
of a pump with a magnetic
coupling will be typically amortized
after only three years of
operation.
The attractive priced investment
is a result of the optimized design
of our new generation.
KRAL has been successfully
manufacturing magnetic coupled
pumps for many years. For
high torque transmission our
couplings utilize high strength
Sm 2
Co 17
permanent magnets.
The maximum energy density of
approx. 400 kJ/m 3 is five times
greater than standard Al Ni Co
magnets.
The magnetic coupling is very
compact. The containment can
is the sealing element of the
pump. Utilizing such strong
magnets, the size of the containment
can is minimized making a
substantial contribution to cost
reduction as well as to reduce
friction and eddy current losses.
The competence of KRAL in
magnetic technology helps lower
the costs for ship owners.
The KRAL pump upgrade
project.
To make the decision easy,
KRAL offers not only the magnetic
coupled pump but also
an upgrade project. In co-operation
with innovative ship owners
we select a ship of the sailing
fleet which needs some
improvements. For this vessel
we offer two booster-pumps, if
requested free of charge, for a
certain trial and return period. If
necessary, KRAL service engineers
can help for replacement
and start-up. After the trial period
we are confident the ship
owner will experience a more
reliable operation, a clean installation
area, and a generally
increased safety on board with
no fuel leakage.
In 2003 KRAL contacted A.P.
Moeller – Maersk in Denmark
about the option to utilize magnetic
coupled pumps for heavy
fuel oil booster units in large
marine installations. To reduce
the life cycle cost, A.P. Moeller
replaced some existing mechanical
seal circulating pumps
with KRAL magnetic coupled
pumps. To be sure that the proposed
technology of magnetic
coupled pumps could improve
their situation, A.P. Moeller requested
a three month trial.
KRAL dispatched their service
engineer to the site and
installed the new pump with
magnetic coupling on the first
Maersk vessel. After the trial
period it was clear that this
technology offered the benefits
A.P. Moeller anticipated.
Thomas Flauger
Product Manager
SPECIAL
13

PARTNER
PG Marine Group.
Real partnership brings global customer benefit.
The PG Marine Group and KRAL AG share a vision: We want to supply
our customers with tailor-made solutions to help them meet the
constantly changing demands of the marine market.
Roy Norum, President and CEO of the PG Marine Group in Norway
(formerly CEO of the COLFAX Pump Group – International Navigation Division).
The PG Marine Group is a supplier
of individual pumps and complete
systems for marine applications.
This includes complete engine
room packages, cargo offload
pumps as well as systems for
tankers and offshore supply vessels
for drilling platforms.
To enable us to quickly and reliably
resolve demanding and
complex tasks for our customers
anywhere in the world,
we maintain partnerships with
leading companies with noted
global brands. What our partners
all have in common is that they
are recognized and competent
specialists in their own particular
areas of operation.
PG and KRAL enjoy a close partnership
which has enabled them,
together, to become genuine global
players. Our success is based
on the common ground shared
by our corporate cultures, one
essential element of which is
innovation. Our reciprocal partnership
enables us to meet the
challenges we face every day and
improve the services we provide
for our customers.
Partnership.
The PG Marine Group concentrates
its business development on
a clearly defined niche market.
Our company operates in the oil
and gas industry in marine and
process engineering. Since the
founding of the company in 1982,
PG’s core area has been the North
Sea offshore market. We have
developed unique technologies
here over the years, which now
enjoy global acceptance and application.
PG is an international operation.
In terms of business volume and
technology, we are the market
leaders in North and South America,
Asia and Europe. Our success
is based on accurate knowledge
of the market, leading products,
and cooperation with progressive
manufacturers.
Market.
PG is an independent engineering
and systems integration business
with its own manufacturing division.
So far this year, our company
has supplied marine equipment
of various kinds to about 100
ships. We are the market leader
for offshore supply vessels. We
have a significant market share
for pump and compressor systems
in the oil industry.
14 special

PARTNER
Innovation.
Together with KRAL, PG supplies
pumps for the anchor winches of
Rolls-Royce Marine. Determination,
a clear message, good products
and above all, the ability
to recognize market trends and
respond to them in the right way
and for the benefit of the customer,
secures us our pole position.
At PG, we have many areas of
application for KRAL products.
Together, we are successful in
areas from which our competitors
have withdrawn.
The advantage that KRAL has
over other marine supplier competitors
can be explained in just a
few statements, which this time
come from someone who was
actually a main competitor actively
looking to refute the following
facts about KRAL:
Flexibility and the will to address
changes in direction at
an early stage.
Products that are designed with
a particular requirement in
mind and which are destined
for a specific application, not
technical installations that have
been borrowed from elsewhere.
Good price/performance ratio
as a result of the facts stated
above.
A complete and steadily increasing
range of high quality
products.
50 years of experience in making
system solutions, which
are superior to those of most
of their competitors.
Resolute in their determination to
expand and develop on the world
market, the PG Marine Group and
KRAL will cooperate closely to
accept the changes that occur in
the marine and offshore business
environment.
Both KRAL and PG are investing
in their infrastructure and their
workforce, to make them fit
the future. By developing new
areas of operation, we are still
on-course for growth. We have
now been working together with
KRAL for 25 years, and this long
tradition of cooperation is set to
continue. We are still in the same
boat with our powerful partners,
because we view this as the best
recipe for future success.
Roy Norum, CEO
PG Marine Group
SPECIAL
15

PaRTNER
Rolls-Royce.
A World Leader in Marine Solutions.
Rolls-Royce, the world’s leading provider of power systems and services for use on land, sea
and air, operates in four global markets - civil aerospace, defence aerospace, marine and energy
markets. It is investing in core technologies, capabilities and infrastructures that can be applied
across these sectors to take a competitive range of products to market. These investments
create high barriers to entry.
derstand who we are and our
business strategy. We seek to
add value for our customers
with aftermarket services that
will enhance the performance
and reliability of our products.
This approach is fundamental to
developing and sustaining collaborative
long-term relationships
Mooring winch.
across all our markets.
operators, 160 armed forces and
Stena Vision.
Rolls-Royce.
A sounding brand.
Rolls-Royce is renowned for
its high-quality world-class products.
Every day we put this
reputation into practice. Wherever
our customers are in the
world, whenever they come into
contact with one of our people,
they expect and receive a high
standard of service. We aim to
be ‚trusted to deliver excellence‘
in everything we do.
A competitive portfolio of products
and services.
According to our strategy, Rolls-
Royce addresses a global market.
We are a leading powersystems
company in civil and
defence aerospace, marine and
energy markets. We manufacture
in 20 countries and serve
customers in 150 countries.
The success of the company’s
products is demonstrated by
its rapid and substantial gains in
market share. Rolls-Royce has a
broad customer base comprising
600 airlines, 4.000 corporate
and utility aircraft and helicopter
more than 2.000 marine customers,
including 70 navies. The
company has energy customers
in 120 countries. Rolls-Royce is
a technology leader, employing
around 36.000 people in offices,
manufacturing and service facilities
in 50 countries. We are
involved in many of the major
future projects in the markets
we serve.
Rolls-Royce. A world leader in
the Marine solutions.
The Rolls-Royce marine business
is a global leader in marine propulsion,
engineering and hydrodynamic
expertise, with a broad
Rolls-Royce has offices, manufacturing
sites or service centres
located in 50 countries around
the world. The diversity of our
people and culture is a key
strength of our global brand.
Our people are building longterm
relationships, helping our
customers and partners to un-
Anchor handling winch plant.
16 special

Stena Caribbean C-Max.
product range and full systems
integration capability.
Rolls-Royce offers a product
portfolio ranging from vessel
design and gas turbine engines
to water jets and deck handling
equipment. The business is
unique in its scope and capabilities,
with the aim of supplying
power, propulsion and motion
control systems for high-value
vessels. The Rolls-Royce marine
business boasts:
7.000 employees.
2.000 customers.
Main manufacturing in the UK,
North America and Scandinavia.
Equipment on over 20.000
vessels.
Sales and service in 34 countries.
Our installed bases are:
Offshore supply and support
- over 800 vessels.
Commercial shipping - over
15.000 vessels.
Warships - 2.200 ships.
Submarines - over 50 boats.
Rolls-Royce Brattvaag.
The Brattvaag facility develops
winch systems and deck machinery
based on Rauma Brattvaag
hydraulic technology for
the merchant and offshore market.
The site has approximately
410 employees and was established
in 1941 on the West
Coast of Norway in Brattvaag,
a small village outside the city
of Ålesund. In October 1999 the
site opened a new FMS-system,
the biggest flexible production
system in Europe, where production
and warehouse administration
is built on the principle
of „on-piece float“ (in contrast
to batch production) and Kanban
control to regulate production.
Cooperation with KRAL.
According to our strategy “Invest
technology“, we contacted the
KRAL AG regarding pumps for
winch plants. The simple target
was to have one more supplier.
We have been amazed that the
discussion with KRAL came to a
very innovative, constructive and
co-operative level. Dr. Christoph
Schneider, Technical Manager
of KRAL, is a brilliant scientist
with a strong focus on feasible
practise. The technicians of both
companies, KRAL and Rolls-Royce,
not only analysed the pump
but also the complete winch
plant. A significant part of the
new and reliable pump sealing
technology was carried out by
KRAL. Both companies invested
in technology to generate added
value for the system and to reduce
life cycle costs.
Charles Kvalvik
Strategic Sourcing Specialist
CoE Deck Machinery
SPECIAL
17

partner
E.R. Schiffahrt GmbH & Cie.
Upgrading to KRAL pumps with magnetic coupling.
The Nordcapital group of companies is active in shipping, real estate and private equity. Since its
foundation in 1992, it has realized an investment volume of around EUR 4,5 billion for its private
and institutional investors. Around 34.000 investors with 46.000 shareholdings and a fund capital
of EUR 1,8 billion are invested in Nordcapital funds. In the shipping funds sector, Nordcapital has
so far set up 85 funds with a total of 94 vessels.
E.R. Schiffahrt headquarters in Hamburg.
The largest subsidiary company
of the group is E.R. Schiffahrt,
which began operations in 1998
with the delivery of the first
three container vessels. Thanks
to Nordcapital‘s financial power,
the shipping company grew
rapidly to its present size. E.R.
Schiffahrt is one of the largest
charter owners of container vessels
worldwide. It is responsible
for project development and
for the commercial and technical
management of 78 container
ships with a capacity of around
350.000 TEU. Of these, 16 units
(100.000 TEU) are under construction
and will be in service
by 2008. E.R. Schiffahrt arranges
charters for the vessels, provides
technical support, as well
as selection and allocation of the
crews, thereby keeping the factors
that are crucial to the success
of the shipping funds within
the group.
Container shipping is a
growth market.
Nowadays the world trade picture
looks somewhat different to that
of a few years ago. Globalization
and the rise of China to become
an internationally significant
economic power require globally
networked logistics systems,
increasing the demand for efficient
and powerful means of
transport. Container shipping
bears the brunt of this in the true
sense of the word and is recording
correspondingly high rates of
growth.
Nowadays, up to 98% of intercontinental
goods traffic goes by doubled every seven to eight
container traffic has on average
sea. For more than 20 years, the years. In 2005, the growth rate
segment that has seen the most was 9,9%.
expansion here is container traffic.
The reason for the tremendous
growth of container shipboard
safety.
Quality assurance and onping
lies firstly in the increasing A safety and quality management
system certified by Ger-
volume of world trade and secondly
in the fact that more and manischer Lloyd in accordance
more varied types of containers with ISO 9001:2000 and ISO
are being transported. Increasing
quantities and ever more with high quality, safety and en-
14001:2004 ensures compliance
efficient logistics concepts have vironmental standards. The safety
and quality management is
reduced transport costs so far
that nowadays it is even viable adapted from statutory provisions
to carry low-cost products and and internal guidelines. Training
semi-finished goods.
programs and regular drills, as
well as monthly ship management
meetings insure that these
Between 1980 and 2004, container
port transshipment increased
virtually tenfold, to realized in daily working practice.
standards are implemented and
about 340 million TEU. So far, Germanischer Lloyd keeps watch
Testing took place onboard a Panamax class vessel, the E.R. Kingston.
18 special

The Post-Panamax class E.R. Canada was also upgraded.
to ensure compliance with ISM,
the International Safety Management
code.
The “pump upgrade” project.
The container fleet at E.R.
Schiffahrt is divided into four
classes. Vessels with the highest
stowing capacity (8.204 to
5.762 TEU) belong to the Post-
Panamax class, because, at over
32,2 meters in width, they can
no longer pass through the Panama
Canal. Then there are the
Panamax class (5.075 to 3.400
TEU), i.e. vessels that can still
just get through the Panama Canal,
and the Sub-Panamax class
(2.825 to 2.226 TEU). The smallest
volumes are transported by
the Feeder class (2.004 to 1.728
TEU). These are vessels that
feed the large units with cargo
from the smaller ports.
Each individual vessel needs intensive
preventive maintenance.
As E.R. Schiffahrt concentrates
on optimizing quality and safety,
in 2004 those responsible were
looking for a permanent solution
to the problem of regularly
having to replace the mechanical
seals in the booster module
pumps. E.R Schiffahrt found a
competent contact in KRAL.
KRAL presented their new development,
the K Series pumps
with magnetic coupling. The negotiating
parties agreed first of all
to a test installation on the E.R.
Kingston, which at 4.253 TEU is
a vessel of the Panamax class.
Four KRAL pumps with magnetic
coupling were installed as
the supply and booster pumps in
April 2005. Testing was agreed
for a period of six months and
results were extremely positive.
Completely satisfied with the
technical solution, E.R. Schiffahrt
also upgraded the pumps
in the booster module on six of
their Post-Panamax class vessels
and on two other Panamax
class ships.
Convincing in action.
KRAL pumps with magnetic
coupling are reliable and tough,
working qualities that are really
appreciated by the engineers in
the engine room.
“As well as KRAL‘s excellent
technical solution, we at E.R.
Schiffahrt particularly appreciate
their technical support and
the communication with KRAL,”
says Uwe Dardaillon, Senior Superintendent
in the team of inspectors
at E.R. Schiffahrt.
Nordcapital
Hamburg
SPECIAL
19

partner
Hot stuff.
Individual booster units for engine-specific conditioning of fuel up to
150 °C in temperature.
It is the customer who decides on success or failure, not the eye of the provider. It is easier to
meet high customer expectations at all times with reliable partners and suppliers. In marine applications,
safety is the order of the day.
In 1893, Westfalia Separator
began designing hand-driven
centrifuges at its Olde facility
in Germany. These have long
since become automatic systems
running “24 hours a day”.
Westfalia Separator has since
diversified and is now a globally
operating organization. With its
trend-setting innovations, Westfalia
Separator is defining international
standards for efficiency,
performance and reliability in
centrifugal separation technology.
In its Mineraloil Systems division,
Westfalia makes booster
units for marine applications.
KRAL has been supplying the
pumps for these modules for
five years.
Building a new ship is a highly
complex project. Thousands of
individual items have to be taken
into consideration during planning
and installation. It makes life
easier for shipyards and shipping
companies if individual, associated
units are combined to make
a system. In addition, modern,
modular systems significantly reduce
engineering and installation
costs for shipyards and shipping
companies.
Booster units for enginespecific
fuel conditioning.
A ship‘s engine will only run
true with optimum fuel conditioning.
With its Visco booster
unit, Westfalia Separator Mineraloil
Systems has developed
a reliable system to ensure that
this is precisely what happens.
The classical heavy fuel oil supply
module adjusts the viscosity,
temperature and pressure
downstream of the day tank exactly
as required by the engine
manufacturer for normal operation
of their machines. By including
this unit into its production
range, Westfalia Separator
is now able to provide heavy
fuel oil treatment both upstream
and downstream of the service
tank. A further piece in the system
technology jigsaw for the
complete engine room.
The newly developed Visco booster units for fuel conditioning meet individual requirements and expectations of the customers.
User-friendly: integrated
control cabinet.
Booster units adjust the temperature
and viscosity of the heavy
fuel oil to precisely meet the
needs of the particular engines
used, and KRAL K Series booster
pumps ensure that there is
the required system pressure
at the injection pumps. The integrated
control cabinet is a key
feature of Westfalia Separator
modules. It houses all the necessary
measuring and control
units and so significantly reduces
the installation effort. It’s modular
design allows the booster
unit to be connected on both
sides, further increasing installation
flexibility. Westfalia Separa-
20 special

A ship’s engine will only run true with optimum fuel conditioning.
tor has also made sure that all
the machine components are
readily accessible, a major advantage
when working on-board
ship. A convenient, user-friendly
interface with a text display on
the front of the control cabinet
simplifies operation.
No problem with sludge
particles.
A persistent issue on-board
ship is the storage, disposal and
cost problems involved with
the sludge particles that occur
when oils are conditioned. This
is why the Visco booster units
include automatic, compressed
air driven backflush filters which
produce a sludge content many
times lower than that of conventional
filter systems which are
flushed by the system‘s own
media. If necessary, several
filters can also be installed in
series to meet the requirements
of the particular engine manufacturer
regarding the quality of the
heavy fuel oil.
Standard in every performance
class.
Westfalia Separator has now
standardized its booster units.
Six different sizes are available
in the 3.500 to 21.000 kW performance
class. By grading its
pump series, KRAL ensures that
a pump of optimum economic
efficiency is always available.
The modules are assembled individually
for higher engine ratings
or special specifications.
Ships are getting ever larger, and
Westfalia is following this trend.
The next step will see standard
units being extended into the
higher performance range. More
options with regard to the filter
and the measuring, control and
regulating units will then also
be available, to meet different
market requirements. As an innovative
partner, KRAL is also
on-board, tracking the trend.
Success in the global market.
The new Visco booster units
for fuel conditioning have been
designed to meet individual requirements
and ideas in every
case and in every performance
category. The Westfalia Separator
booster unit has already
scored its first major success
in the Japanese shipbuilding
market.
Westfalia Separator AG
Oelde
The new Visco booster units adjust the temperature, viscosity and pressure of the heavy fuel
oil exactly as required by the engine.
SPECIAL
21

partner
A long service life despite Cat Fines.
Kupke+Wolf GmbH – safely state-of-the-art.
Improved refinery techniques are detrimental to the quality of the residual
oils being used by the shipping industry as fuels. These heavy oils are
contaminated with Cat Fines and make great demands on suppliers.
Kupke+Wolf have been providing safe concepts for engine protection for 25 years.
A Kupke+Wolf booster module.
The increased demand for fuel
is detrimental to quality.
The residual oil used as the base
material for heavy oil and bitumen
is produced during atmospheric
distillation at petroleum
refineries. In modern refineries,
this residual oil is reprocessed
to cover the increased global demand
for gas, petrol, kerosene,
diesel oils and lubricating oils.
This is done, for example, by catalytic
cracking, which „chops“
the complex carbon chains with
the aid of a catalyst. This process
again produces different fractions,
from which HFO, among
others, can be blended.
However, the heavy oil (HFO,
RMK) is contaminated with
residues from this catalytic
cracking, such as aluminum silicate.
Although these so called
Cat Fines are limited under the
ISO 8217 Fuel Standard, their
highly abrasive properties greatly
reduce the life of the engine
components.
Modern fuel modules protect
the engines.
Fuel supply modules are installed
in the ship‘s engine room
between the service tank and
the engines. The pumps, filters,
tanks, heat exchangers, measuring
instruments and control
fittings are installed on a base
frame. Although fuel quality is
steadily getting worse, engines
are responding more and more
sensitively, which poses enormous
problems for the component
suppliers.
Heavy oil is pre-purified in the separator
and reaches the module
from the service tank through a
system of pipes, at about 80 °C.
The fuel reaches the mixing tank
via preliminary filters, booster
pumps, automatic filters and the
volumetric meter. Tubular heat
exchangers are installed in the
circuit after the mixing tank and
the pumps. These preheaters
heat the fuel sufficiently to meet
the injection viscosity prescribed
by the engine manufacturers. A
viscosity, metering and control
unit controls the process. The
conditioned fuel reaches the
engine via an indicator filter.
The demands on fuel conditioning
increase.
Kupke+Wolf work closely together
with filter manufacturers,
universities, classification societies
and engine manufacturers
and have known for many years
that 10 µm filtering is necessary.
Cat Fines and the other solid
constituents in heavy oils shorten
engine life considerably if
they are not reduced to a minimum.
Cat Fines between 5 and 40 µm
in size have been found in filter
mats, in heavy oils and embedded
in engine components.
This has resulted in engine damage,
so superfine filtration of
10 µm is an important safety factor.
The fully automatic backwash
filter is preferably installed in the
fuel module’s feed system.
22 special

The method of filtering propagated
by Kupke+Wolf GmbH
provides maximum operational
safety, as the volumetric meter
and the circulation pumps are
also protected by fine filtering.
A bypass filter and another indicator
filter directly before the
engine are also installed for redundancy.
A longer service life with KRAL
pumps.
If the same maintenance intervals
are to apply to the fuel
module as to the highly developed
engines, the circulation
and booster pumps must also
be designed for this. The pump
component that is maintenanceintensive
is the mechanical seal.
Whenever possible, we now rely
on KRAL pumps with magnetic
coupling. The magnetic coupling
fully replaces the mechanical
seal. These pumps can be designed
for up to 250 °C. As the
coupling works without contact,
the abrasive Cat Fines can no
longer cause the seal to wear.
Kupke+Wolf modules safeguard
engine operation.
The competence acquired by
Kupke+Wolf GmbH through 25
years and more than 1.000 modules,
has earned them the trust
of engine manufacturers, shipyards
and vessel operators. Their
international service provided by
the company puts Kupke+Wolf
GmbH so close to the market
that their modules and component
range are adapted to the
latest requirements.
Kupke+Wolf GmbH work together
with experienced, established
suppliers to safeguard
operation. The steadily increasing
demands made on the materials
and the range, require
maximum innovation from suppliers,
as well as reliability that
has stood the test of time.
Dipl.-Ing. Susanne Wolf
Development and Standardization
Kupke+Wolf GmbH
SPECIAL
23

PARTNER
Fuel Consumption Measurement in
Harsh Operating Conditions.
MTU Friedrichshafen enables its customers to verify fuel consumption
using the KRAL Volumeter. ®
Fuel consumption is an important criterion when investing in large capacity
diesel engines. Operators have long desired a consumption measurement.
MTU Friedrichshafen has fulfilled this customer requirement and offers the
KRAL fuel consumption measurement system. However, that alone is not
enough for these two innovative companies. MTU and KRAL have optimized
the system for the harshest of operating conditions.
MTU Friedrichshafen, a Daimler
Chrysler AG company, ranks
worldwide among the leading
manufacturers of large capacity
diesel engines and complete
drive systems. With more than
6.000 employees worldwide
MTU has achieved a turnover
of more than 1 billion Euros
(Year 2000). The company produces
engines and works for
application areas in shipping,
power supply, heavy vehicles
and railway. All areas are in the
capacity range from 35 to 9.000
kW (50 to 12.250 HP). In its own
product center, MTU Friedrichshafen
manufactures articulated
shafts for passenger cars and
light commercial vehicles. With
the development and production
of the „Hot Module“ high temperature
fuel cell and the PEM
fuel cell, the company is working
on the next genera-tion of
drive and energy generation systems.
With ten subsidiaries on
all continents and a solid sales
and service network, MTU has
a worldwide presence. The Off-
Highway activities of the Daimler
Chrysler Corporation have
been incorporated in the Power
Systems Off-Highway business
unit under the management of
MTU Friedrichshafen.
Product offensive: Series 8000
with 9.000 kW.
On the occasion of the shipbuilding
exhibition SMM, MTU
continues its product offensive
as started in 1996: For the first
time, the new Series 8000 is
being presented. With the 20-
cylinder version and an output of
9.000 kW, the company is opening
up a new field of services.
The series is based on a newly
developed concept and meets all
requirements placed on modern
engines.
MTU Engines for a broad application
area.
For the installation of the 20V
8000 in commercial ships
the continuous engine output
amounts to 8200 kW. Both the
conception and the technology
of the product line permit a clear
performance increase, which
MTU will implement given a corresponding
market requirement.
With its new product line, MTU
expects not only to strengthen
its strong position in this market,
but also to expand its position
particularly for ships over 50
meters in length. For this application,
where shipyards and operators
over the next ten years are
count-ing on constant demand,
the company offers the most
modern drive solution with the
24 special

The 20V 8000 is one of the first four-cycle engines of the 8-10 MW Class, where Common Rail injection is a standard.
20V 8000, which at the same
time has the potential of being
able to fulfill future requirements.
Yachts: There is continuous
growth in regard to mega yachts.
Vessels with a length of over
100 m are no longer a rarity. MTU
has been carefully following the
new 8000 Series.
Power supply: In terms of
construction the 8000 Series has
been designed for diesel, gas
and heavy oil versions in such a
way that it can also be used in
peripheral energy system applications.
Economically attractive due to
low life cycle costs.
One of the objectives defining
the development of the 8000
series was to minimize the life
cycle costs of the propulsion
plant. MTU therefore placed
great emphasis on keeping fuel
consumption as well as the maintenance
and service costs of the
new engines low. When deployed
in fast commercial ships, the
fuel consumed by the 20V 8000
lies, over a wide operating range,
below 195 g/kWh. At its best performance,
it remains below 190
g/kWh - always in keeping with
the IMO (International Maritime
Organization) limit values for nitrogen
oxide (NOx). On the basis
of these values, the new engine
attains the lowest fuel consumption
in its performance class. The
common-rail injection system
and sequential turbo-charging
have especially contributed to
making this possible.
Fuel Consumption Measurement
with KRAL Volumeter.
In cooperation with KRAL, MTU
Friedrichshaven has defined fuel
consumption measurement systems
for the 2000 and 4000
Series and labeled these using
MTU part codes.
We now offer our customers an
extremely interesting option.
Using the KRAL system, ship
operators can now check immediately
whether they are running
economically in regards to fuel
consumption. All engine-related
difference measuring systems
have temperature compensation.
Thus, we can offer a measuring
accuracy, which are not attainable
using tank level measurements.
KRAL is currently working with
us to equip the 8000 Series with
a fuel consumption measurement
system. We assume that a
major benefit will be recognized
and that the system will also be
used with our newest product
lines.
Innovation for harsh environmental
requirements.
MTU engines are frequently exposed
to harsh operating conditions.
In engine rooms and on
bridges, all components must
cope with strong impacts, vibrations,
high temperatures and
more. In addition, a CANopen
Bus link is important to us. Here
KRAL has proven to be an extremely
cooperative partner, with
whom we are setting up our system
for its high demands.
We are also sure that our cooperation
will offer our customers additional
value in the future.
Daniel Reinhardt
Press Manager
MTU Friedrichshafen GmbH
SPECIAL
25

PARTNER
World Class Diesel Engines.
Spotlight on Caterpillar’s German locations.
The only constant is change. This especially applies to diesel engine
production at the Kiel-Friedrichsort location, where the last eighty
years have seen frequent changes in ownership and company name.
A significant event occurred three years ago.
Air photo of Caterpillar Motoren Rostock GmbH.
Air photo Caterpillar Motoren GmbH & Co. KG, Kiel.
At the beginning of 1997, Caterpillar
Inc., Peoria acquired the
company from Fried. Krupp AG
Hoesch-Krupp and its name
was changed to MaK Motoren
GmbH & Co. KG. Since August 1,
2000 the company has conducted
business as Caterpillar Motoren
GmbH & Co. KG for the
Kiel location and as Caterpillar
Motoren Rostock GmbH for
the Rostock location. This was
done since the parent company
wished to stress the strategic
importance of the two German
locations within Caterpillar’s
global engine business and the
implementation of its ambitious
growth strategy. It was also intended
to reinforce identification
with these two locations.
Today, Caterpillar is the largest
manufacturer of diesel and gas
engines worldwide. The Kiel location
is the technology center
for large, medium-speed diesel
engines within the Caterpillar
group. The factory, bought in
1999 from the assets of the
Rostock GmbH (DMR) diesel
engine factory, is an additional
production location for the
assembly of the largest engine
series, the M 43.
High brand acceptance.
For over eighty years diesel
engines have been developed,
distributed worldwide and serviced
in Kiel. For the first thirty
years it was under the D label
of the Deutsche Werke AG, and
since 1948 under the MaK trademark.
The engines produced in
Kiel and Rostock for the marine
market are marketed today under
the well-known „MaK“ trademark,
while engines for power
generation and the oil industry
carry the „Cat“ logo. Both trademarks
have high market acceptance
and will be maintained as
independent names.
Research and development.
Engine development programs
are constantly focused and organized
to meet market requirements
and customer demands.
The current long-stroke engine
program was introduced to the
market from 1992 in two-yearly
cycles. The engine series M 20,
M 25, M 32 C and M 43 have
power ratings from 1.020 kW to
16.200 kW.
The objectives of the research
and development work are to
achieve higher performance,
higher efficiency, improved reliability,
ease of operation, and optimal
environmental compatibility.
The international success of the
engines is based on the motto:
„Man + Machine = Quality“. It
is only possible to satisfy the
requirements for long-term high
quality by having skilled and motivated
staff and advanced machines.
Therefore, quality control
of Caterpillar engines starts with
the selection of supplier companies
and runs through all internal
processes up to testing and approval
of the finished product.
26 special

PARTNER
Advantages of fuel consumption
measurement.
Measurement of engine fuel
consumption is an important parameter
for running engines efficiently.
Low operating costs
are also good selling points.
Since consumption figures are
often included in contracts, measurement
of fuel consumption is
important. Caterpillar engines
are fitted with a KRAL fuel consumption
measurement device.
These devices are used in the
engine development test field
at Kiel and in the test bed and
approval area at the Rostock
location.
An engine developer’s priority
is to achieve the lowest possible
fuel consumption and lowest
possible emissions. This requires
reliable instruments that
avoid human errors and allow a
certificate of consistent quality
to be produced. An objective
assessment of the components
used in the injection and
combustion processes is then
possible.
Volumeter precision is
helpful.
When an engine series is being
tested for approval, it is important
for the test bed facility to
be fitted with fuel consumption
measurement devices that can
assure the highest possible accuracy
and reproducibility of
measured values. When determining
an exact value for fuel
consumption it is also necessary
to measure the values
for braking load and revolutions
as well as fuel mass flow. For
measuring mass flow a different
method from KRAL is used.
A test certificate at the click
of a mouse.
The test bed monitor displays
the recorded and calculated data,
second by second. Not only fuel
data is displayed, but also all other
data required for inspection
and approval are automatically
View into one of the modern test facilities.
recorded. The measurements for
completing the test certificate
are started at the click of a mouse
and stored on the server. All engine
test certificates and acceptance
reports are stored and can
be retrieved at any time. The basic
testing acceptance certificate
provides both the customer and
service department with an assessment
of the engine in the
event of warranty claims or particular
operational conditions.
Use of the KRAL fuel consumption
measurement feature is
important. It not only provides a
significant competitive benefit
in terms of consumption and
technology, but it also provides
a safeguard for the consumption
figures stipulated in the purchase
agreement, allowing future warranty
claims to be minimized or
prevented.
H. Jürgen Homeyer
Caterpillar Marine Division
Marketing Support
www.cat-marine.com
www.mak-global.com
The four series cover ratings from 1.020 kW to 16.200 kW.
SPECIAL
27

PARTNER
Aalborg Industries
Marine Boiler – MISSION Accomplished!
World leading brand in marine boilers.
Aalborg Industries has positioned itself as the
absolute world-wide market leader in marine boilers.
MISSION D-type
boiler featuring steam
capacities in excess of
100 t/h.
The MISSION series now
comprises a full range of oil-fired
boilers and exhaust gas economisers
for the Marine Industry.
Steam capacity ranges from
1.6 t/h to 110 t/h.
KB Burners.
Aalborg Industries designs and
manufactures its own brand in
burners – KB Burners – applicable
for our full range of marine
boilers.
The KB Burner types supplied are:
Pressure Jet
Rotary Cup
Steam Atomising.
Capacity ranges from 1.7 to 47
MW on a single burner installation.
To achieve a large turn down
(10:1), without compromising
performance and flame stability
on large and medium sized
steam atomising burners,
utmost accuracy is needed in the
control of the fuel / air ratio.
For this purpose our combustion
control system relies on KRAL
Volumeter ® to provide an accurate
measurement of the oil flow.
The KRAL Volumeter ® has been
an integral part of the KB burner
design for 12 years - adding to
the reliability of the burners with
its sturdy design and reliable
operation.
These are highly valued features
on board sea-going vessels.
MISSION Concept.
Aalborg Industries set out on a
MISSION back in 1994, introducing
a new concept in marine
boilers based on more than 75
years of comprehensive experience
in the development, production,
supply, and service of
marine boilers and steam
systems.
The MISSION series of boilers
were born featuring low weight,
high efficiency modular boilers
delivered as complete units
including burner and burner
controls.
Final workshop inspection of KBSA oil fired burner for MISSION D-type.
28 special

VLCC equipped with Aalborg Industries MISSION Boilers.
Aalborg Industries produces
more than 100 large steam atomising
burners annually for
MISSION OL and MISSION
D-type boilers.
These boiler types are applicable
for Tankers and other vessels
characterised by large steam
demand for cargo heating.
The Future.
Aalborg Industries constantly
strive to accomplish the MIS-
SION by developing and designing
new boiler solutions to customer
demands.
Jørgen Munch Nielsen
Mechanical Engineer
Burner Section
Aalborg Industries A/S
Denmark
Service network.
Aalborg Industries employs
1.600 people world-wide – all
equally dedicated to the support
of customers.
Companies are located in key
ports throughout Asia, Middle
East, Europe and the USA,
offering swift service, repair and
spares delivery.
KRAL Volumeter - OMG Series.
SPECIAL
29

partner
KRAL fuel consumption measurement
helps Dutch fishermen to
save money.
Higher profits despite the constant increase in fuel prices.
Gas oil is the main fuel used by the fishing industry. Continually rising fuel prices are increasingly
pushing fisheries to the limit of profitability. Thanks to KRAL fuel consumption measurement,
the Dutch fishing business now has an improved chance of survival in the globalization market.
We, the Lokker family, have been
working in the fishing industry
for 43 years. Our family-owned
business in the lovely fishing village
of Goedereede in the southern
Netherlands was founded by
our father and his brothers. We
are the two sons, Cor and Gert,
and we joined the firm in 1983.
Our uncle left the firm in 1993
and our father passed away in
2000, after which our mother
took over his position. Our fishing
business, Jan Lokker & Zonen,
has two fishing boats, the
GO 22 “JAN CORNELIS” and
the GO 26 “ARENDJAN”. In the
old days, you could earn good
money catching fish. Nowadays
fishing has become unprofitable
for many. We are passionate
fishermen, but even we are
starting to suffer from the daily
battle for survival. It is not just
the quota controls imposed by
the EU on fishing, but also the
increase in fuel prices that have
driven up costs. The price of
fresh fish, however, has not increased
in recent years.
In a conversation at Maaskant
Shipyards, we discovered that
the GO 26 “ARENDJAN” boat
had been fitted with an on-board
consumption measurement system,
however, it was not working
properly, and not being used.
When the Dutch KRAL agency Intercontrol
Meet- und Regeltechniek
became aware of this, they
offered me a KRAL fuel consumption
measurement system.
First I was skeptical, but then I
finally agreed. A KRAL fuel consumption
measurement system
was installed for the Deutz TBD
645 engine with 1.470 kW. Once
the two flowmeters (KRAL OMG
Volumeter) had been successfully
installed and commissioned,
together with the corresponding
KRAL BEM 500 electronic unit,
I looked forward eagerly to the
next trip. The crew sets off for
the open sea on Sunday evening
and they are usually based there
until Friday. After a few weeks,
I was happy to report my initial
experience.
Saving fuel on the trip to the
fishing grounds.
The boat headed for the fishing
grounds in the North Sea at 12
miles an hour (22,2 km/h), with
a fuel consumption of 330 liters/h.
With the KRAL consumption
measurement system fitted,
it is possible to measure fuel
consumption, compare it with
the engine speed and thus determine
the optimum speed of
travel. Curtailing the speed by
0,5 miles an hour (0,9 km/h)
saves 30 liters/h, which reduced
total fuel consumption to 300 liters/h.
The journey is only 5 minutes
longer, but the fuel saving
is 10%. We save far more money
by using less fuel than by taking
the slightly shorter time to reach
the fishing grounds.
Saving fuel when fishing.
Once we reach the fishing
grounds, the net is lowered into
the water and the boat chases
after the shoals of fish at high
speed. Factors, such as the size
of the mesh of the net, the weight
of the net, its hydrodynamic design,
and the chains to which the
fishing net is fixed, all contribute
to the drag resistance in the water.
High drag resistance instantly
causes higher fuel consumption,
so we have to reduce fuel consumption.
As is generally known,
it is the last engine revolutions
at full load that cause the highest
consumption. We reduce the
speed of the engine and travel at
even speed, keeping an eye on
the fuel gauge. When the speed
indicator then responds, that
is to say, also goes down, the
consumption indicator is already
showing a perceptibly reduced
figure. A saving of 1,5% makes
a great difference.
Converted to a weekly total fuel
consumption of about 36.000
liters of gas oil, you save at
least 540 liters. Over an entire
year, this means that a KRAL
fuel measurement system has
paid for itself in only eighteen
months.
GO 26: even in stormy seas, the KRAL fuel consumption measurement system works as
reliably as usual.
30 special

GO 22, fishing at full speed in the North Sea.
KRAL fuel consumption
measurement for diesel engines.
The best thing about KRAL fuel
consumption measurement systems
is that no matter how high
the engine speed, you can see
the current hourly consumption
rate straight away. The manufacturer
specifies the low pressure
fuel system. KRAL is the
only system supplier who takes
all the standards into consideration
in its system configuration.
Separate measurement of forward
and return flow, each with
its separate flowmeter, as well
as temperature and pulsation
compensation, are available as
a complete system. The ease
of installation and the highprecision
measuring accuracy
over a wide engine load and
speed range make this system
unique. Because of error propagation,
it is important for each
of the individual measuring devices
to be highly accurate so
that the complete system can
measure accurately during differential
measurement. The devices
also boast a highly robust
design, which is very important
on board the ship. The flow rate,
the total volume, and fuel consumption
can be read on the
bridge at any time.
After our success with the GO
26, we also fitted the newly
built fishing boat, the GO 22,
with a KRAL fuel measurement
system. The boat began operation
on January 26, 2006. Once
again, we are very happy with
our experiences so far. We continue
to have a great deal of
confidence in the KRAL fuel consumption
measurement system.
The 7-person team at Intercontrol
Meet- und Regeltechniek
are also delighted that we can
see such satisfying, practical
opportunities to save money, every
day.
Cor and Gert Lokker
Jan Lokker & Zonen
Goedereede, The Netherlands
It is even possible to save fuel at full speed.
SPECIAL
31

KRAL -USA
Motor Yacht „Lara“.
Lara’s new captain seeks fuel consumption measurement system to
improve engine performance at sea.
A west coast yachtsman recently acquired the Motor Yacht Lara. With a new
boat in their care, Captain Andy Cranmer and Manager Richard Catlett were
charged with retrofitting the entire vessel for the new owner’s purposes.
The 125 ft. luxury yacht would be updated to accommodate up to 10 passengers
on world cruises for extended periods of times.
During the retrofitting, the Lara
visited Seattle, Washington,
USA. Captain Cranmer found
the resources of PG Marine LLC
of Bellevue, Washington for
KRAL fuel consumption measurement
equipment.
Lara‘s need for fuel
consumption measurement.
The Lara is equipped with two
Caterpillar 3508 engines for propulsion.
Each engine has throttle
and drive shaft engagement adjustments.
To change the propulsion,
the captain can vary the engine
speed up or down. He can
also regulate the level of engagement
in the drive shaft. The
balance of these two adjustments
depends on many variables
and, before now, there was
no measurement available to
find the optimum combination.
One advantage of using precise
fuel consumption measurement
is that the captain has the data
at his fingertips to make fine adjustments
and find the optimum
settings according to the current
conditions. As wind, currents,
chop, and weather
change, he knows the exact
consumption rate of the engines
and can adjust to find the
optimum setting. With 1000+
mile journeys, even the smallest
change can save an enormous
amount of fuel.
Another advantage of precise
fuel consumption measurement
is that engine maintenance
cycles can be extended. Caterpillar
recommends engine maintenance
intervals on the fuel
consumption of the engine. If
that is not available, the run
KRAL fuel consumption displays in the
Lara’s wheelhouse.
time of the engine is used. With
run time, however, the maintenance
intervals are much shorter.
Both time and money can be
saved using real fuel consumption
measurement data.
Equipment.
As a further enhancement, PG
Marine offered the function of
datalogging to the Lara. Datalogging
can be installed as a
compliment to the KRAL equipment
and allows a detailed history
to be taken. Long-term
trends are easy to see in this
manner.
KRAL Volumeter installed in the Lara‘s
engine room.
East Coast of the United States,
Captain Cranmer benefited from
his new instrumentation. „With
the KRAL system, the guess
work of engine analysis is history.
It‘s like having a microscope
in the engine room. Accurate
fuel consumption measurement
gives you vital information about
your engines, which are the
heart of your ship.“
Rich Meighan
Sales Manager
KRAL - USA, Inc.
As an existing craft, the Lara
needed to retrofit the KRAL
system. Little extra space
remained in the engine room
for flowmeters. With a compact
design of the KRAL Volumeter,
they were fitted near the engine
without protruding into
walkways or workspaces.
Experience with the KRAL System
on Lara‘s first voyages
proved successful. From Cali-
The Lara.
fornia, to Central America to the
32 special

Not every fire is
so romantic ...
Increased Onboard Safety Through KRAL
Pump Upgrade Project.
Reducing Fire Risk in the
Engine Room!
Special offer for the Marine!
KRAL screw pumps with hermetically sealed
magnetic coupling.
Shaft seals in fuel oil pumps for boostermodules
in the engine room will
always remain a critical element. Even
by normal operating conditions they
will succumb to wear and the risk
of fuel oil leakage is ever present.
Heating the fuel oil to temperatures
over 130 °C can cause fires. This risk
is greatly reduced when using KRAL
magnetic coupling pumps.
KRAL Pumps with Magnetic Coupling.
Several years ago the magnetic coupling
was developed as an alternative
for pumps with shaft seals. KRAL
magnetic coupling pumps are hermetically
sealed. Fuel oil leakage and fire
incidents are greatly reduced with our
technology.
Pump Upgrade Project.
To make the decision easy for shipowners,
KRAL offers a test time for
two booster pumps with magnetic
coupling. The test is cost free and
KRAL service technicians are available
if necessary to assist with the installation
and during start up.
Visit us at
www.kral.at
or contact us directly.
KRAL AG, Bildgasse 40, Industrie Nord, 6890 Lustenau, Austria, Tel.: +43 / 55 77 / 8 66 44 - 0, Fax: 8 84 33, E-mail: info@kral.at

KRAL AG, Bildgasse 40, Industrie Nord, 6890 Lustenau, Austria, Tel.: +43 / 55 77/ 8 66 44 - 0
Fax:+43 / 55 77/ 8 84 33, www.kral.at, E-mail: kral@kral.at
KRAL INSIDE SPECIAL 09/06