Stop losing money to short-delivery. The Insatech Bunker Management System provides a complete bunker fraud prevention solution for marine fuel oil. By monitoring flow, density, and temperature in real time with extreme accuracy, the system instantly detects fuel manipulation. Protect your profits with verified data and ensure you always receive the exact mass of fuel paid for during every single bunker operation.
For sales or commercial inquiries please contact us at marine@insatech.com.
In June 2013, the Insatech Bunker Management System documented a short-delivery of 53.3 Metric Tons during a single bunker operation, equivalent to USD 31,980. This single detection paid for the system investment immediately.
Fuel expenses constitute 50% to 70% of a vessel’s total operational costs, making short-deliveries (often 3% to 4%) a massive expense. The manipulation occurs when bunker volume is inflated by intentionally introducing air into the marine fuel.
The Insatech Solution: The system utilizes a state-of-the-art Coriolis Mass Flow Meter to safeguard your investment. It precisely measures and logs:
Proven in practice over six years and installed on more than 50 vessels worldwide, the system gives you complete assurance. We recommend integrating our Performance Monitoring System for total fuel consumption knowledge.
Over the last decade, the rising cost of fuel has increased the incentive for bunker delivery services to actively affect the properties of delivered marine fuel oil. This leads to two primary problems for vessel operators:
Volume-based measurements are fundamentally unreliable because fuel volume changes with temperature.
By raising the temperature of the marine fuel oil during bunkering, the bunker supplier can intentionally increase the oil's volume. This gives the impression of delivering a larger quantity than what is actually delivered, leading to immediate short-delivery.
It is common practice to determine fuel quantity by sounding tanks and then converting the measured volume to mass using conversion tables, causing high volume uncertainty.
If air is introduced into the Heavy Fuel Oil (HFO) bunker stream, the volume will appear larger than the actual fuel mass delivered. The air can enter through several intended or unintended entry points, such as stripping during tank changeover.
This intentional volume manipulation is known as "The Cappuccino Effect."
"The Cappuccino Effect": This occurs when air is let into the bunker line, continuously manipulating the volume. The resulting tiny air bubbles are often invisible and hard to detect during sounding, and the fuel can stay aerated for days or weeks. This delay often prevents claims, as disputes must typically be made within 48 hours.
The clear advantage of the Insatech Bunker Management System is that it utilizes a Coriolis Mass Flow Meter instead of an unreliable volumetric flow meter.
This means:
Mass Flow is Measured Directly: The measurement is not influenced by air entrained in the oil or fluctuations in temperature and density.
Automatic Fraud Detection: The system actively monitors the differential pressure across the flow meter and the media temperature. This ensures automatic entrained air detection and stable bunker operation logging.
By understanding the factors that influence bunker operation and applying precise, trustworthy instrumentation, you secure the optimum position when taking on marine fuel.
Discover the value of having a proactive tool monitoring bunker operations and giving alarm if density drops.
Host: Henrik Nielsen, Sales Manager.
The Insatech Bunker Management System is built on reliable and tested instrumentation to ensure efficient detection of non-compliant bunker operations, whether intentional or unintentional. The system is designed to seamlessly aid your crew during bunkering while ensuring headquarters have comprehensive, stored data via the reporting feature.
The main component of the Bunker Management System is the Mass Flow Meter, operating on the Coriolis principle.
Core Function: It directly measures the mass of the fluid passing through it.
Key Advantage: This measurement is unaffected by air entrainment (air in the marine fuel oil), temperature, density, or viscosity, providing the ultimate safeguard against volumetric manipulation.
The system is equipped with advanced sensors that go beyond simple flow measurement:
Pressure Transmitters: These are placed strategically before and after the flow meter. They are required for the detection of air in the bunkered marine fuel oil.
Advanced System: The transmitters also aid in regulating line pressure and flow rate by controlling a valve placed downstream of the flow meter. This valve is also used for a slow start-up, enabling safe venting of the bunker hose and pipes.
Temperature Transmitter: Included in the setup to further heighten the overall precision of the monitoring process.
All signals drawn from the instruments are received, stored, and processed within the control cabinet, which handles all system communication and data logging.
The data collected from all sensors is automatically used to generate a comprehensive, tamper-proof Bunker Report. This report is highly useful both during bunkering and in the event of a bunker dispute.
The report automatically includes all necessary, verified information:
Bunkering time and duration
Average density and temperature
Flow rate and total mass delivered
Viscosity data
If the advanced system is installed, the report will also include a value for the stability index of the complete bunkering operation. This stored data can be recalled at any time, ensuring you have the evidence needed to settle any claim.
Insatech Marine has developed and designed the operator interface with a focus on functionality and easy operation. We recognize the vital need for a user-friendly system, as it will be utilized by diverse crews with varying nationalities and experience levels.
The simple operation of the Bunker Management System directly translates into compliance and reliable data integrity.
Minimalistic Design: The interface features a clean, minimalistic design that eliminates confusing elements and unnecessary information. While the display is simple, all in-depth and full data remains readily available to any user without compromising the system's compatibility or integrity.
Crew Aid: The intuitive interface significantly eases the process related to raising protests and claims towards bunker suppliers, giving your crew the immediate upper hand.
The system is designed for instant usability after installation, requiring only a fast, initial setup:
Enter basic identifying information (ship’s name, IMO number, and other obligatory data) just once.
The system will continuously use this saved data for all future displays, logs, and automatically generated Bunker Reports.
This one-time setup ensures quick adoption and consistent, error-free data logging across all bunker operations, regardless of crew changeover.
The Insatech Marine Bunker Management System is designed for maximum ease of use. All essential information is accessible with one touch of the screen, ensuring crew members can operate the system efficiently and accurately, regardless of their technical background.
The system's Overview Display provides an immediate, visual status check of the entire operation. This central screen presents all information needed during bunkering, including:
Intuitive graphic illustrations showing the current status of the system's different stages.
Flow, Density, Viscosity, and Trends visible during the transfer.
The "Start Bunkering" display minimizes preparation time and reduces the chance of human error.
The operator quickly enters the necessary input (e.g., fuel type, quantity target).
Once data is entered, the system is ready to begin.
The operation is activated by the press of one single button, engaging the Bunker Management System immediately.
Upon completion of the operation, the system automatically handles the crucial documentation step.
All detailed logs and information are saved in an official Bunker Transfer Report (BTR), formatted as a PDF file.
This digital report can be easily printed or sent to headquarters via email, eliminating manual data entry and ensuring the immediate availability of tamper-proof evidence for dispute resolution.
This streamlined workflow ensures that the crew can focus on the physical bunkering task while the system automatically manages complex data logging and reporting.
The Insatech Bunker Management System combines precise metering with automatic control features to ensure operational stability and immediate fraud protection throughout the transfer.
The core of the system uses the Coriolis Mass Flow Meter with enhanced functionality provided by key components:
Pressure and Temperature Transmitters: These ensure heightened precision and functionality.
Automatic Control Valve: This valve helps maintain sufficient back pressure during the transfer. It also provides the ability for an automatic and controlled partial shutdown of the operation if the delivered fuel is detected as non-compliant or inconsistent.
A comprehensive Bunker Transfer Report is generated automatically after each operation and is stored securely within the system. This tamper-proof report provides all critical data points:
Average density and temperature
Air content and flow rate
Fuel type and logistical information
The collected bunker operation data is instantly available and can be accessed at all times by both the crew and shore-based operations.
Transmission: Data is transmitted via the ship’s own internet connection immediately upon operation completion.
Shore Use: Headquarters gain immediate access to current and historical reports, which is essential for statistical analysis and financial verification purposes.
The system is a crucial action enabler, signaling the crew and shore when immediate intervention is required.
Local Alarms: The system is configured to signal an alarm instantly in the case of faulty deliveries or quality inconsistencies (e.g., high air content).
Remote Alarms: Critical alarms that require immediate action or assistance from land-based operations can be sent directly to Headquarters.
Critical Compliance Note: Since dispute claims often must be made within 48 hours of bunkering, the ability to take action in due time via remote notification is critical for protecting your investment.
Depending on what your needs are and how you wish to use the Bunker Management System, there is a configuration that will fit. The system is made in two setups Standard and Advanced. Both includes a cabinet for signal processing and a touch screen for operation.
Standard setup consists of a mass flow meter, a temperature transmitter for more accurate readings and better compensation as well as two pressure transmitters, which are used to compensate for viscosity. The system requires manual input of viscosity and temperature from the BDN (Bunker Delivery Note). The system is mainly used for MGO (Marine Gas Oil).
Advanced setup includes a control valve enabling air detection, slow start feature and critical operation shut-down. The Automated setup will act upon changes in the bunker flow, give alarms on predefined set-points and can be programmed to close to a 15% flow automatically in case the delivery does not comply with expected quality. This system is intended for high viscosity fuels such as HFO (Heavy Fuel Oil).
The system installation does not generate unnecessary costs, it will not alter your schedule or put your vessel out of service. Our experienced technicians install and commission the system while your vessel is in service, whether at sea, in port or dry dock. We are ready to move out at your preferred destination and time.
The system is programmed, calibrated and has been initially setup by our technicians to minimize installation time onboard. The crew on board will in some cases be able to install the equipment under the guidance of Insatech Marine’s technicians, to ensure correct placement and electrical installation. This minimizes cost and required man-hours, while ensuring maximum benefit of the system during use. However, we are also able to provide installation with commissioning, tests and training of the crew. We can complete the installation at sea, in port or dry dock at your preference.
Turnkey solutions and installations; at sea, in port or dry dock at your preference.
If you require a service agreement as part of the system our skilled technicians are ready to service your vessel at all times. While the system requires minimal maintenance an occasional calibration of equipment is recommended.
To constantly get highly accurate measurements, your marine equipment must function optimally. This means it must be calibrated according to the purpose, and therefore we provide service options, should the need arise. This is why we have our own technicians ready for service on board your vessel at all times, whether it is a planned service visit or a pressing and acute matter that needs immediate attention.
As the equipment used for the Bunker Management System is mostly constituted by components without moving parts, the need for active maintenance is minimal. Nonetheless there might be equipment in need of calibration or service from time to time, and depending on the specific setup, a service and maintenance plan will be issued with each individual Bunker Management System.
This BMS uses Coriolis mass flow measurement and monitoring to stop bunker fraud and short-delivery in real-time. It safeguards operators by detecting air and manipulation.
It measures mass directly, monitoring density and temperature to identify anomalies. It detects the "cappuccino effect" and flags manipulation with a secure, time-stamped audit trail.
Mass flow measures the actual mass delivered, immune to temperature, density, or air entrainment. Volumetric measurement is easily manipulated and relies on inaccurate tables.
Air is intentionally introduced to inflate fuel volume, causing fraud often missed by sounding. Our mass flow measurement ignores this, eliminating the "cappuccino effect."
Core components are the Coriolis Mass Flow Meter, pressure/temperature transmitters, and an intuitive interface. The Advanced setup adds a control valve for flow and air detection.
High-accuracy, real-time data ensures precision. Documented cases show savings exceeding 50 metric tons, often providing full ROI in a single bunker operation.
Standard (for MGO) provides mass/pressure measurement. Advanced (for HFO) adds an automatic control valve, air detection, and automated flow reduction for quality control.
Yes. We recommend integration with our Performance Monitoring System for full fuel consumption insights and comprehensive operational optimization.
Yes. The interface is minimalistic and effective for all crews. Operation requires only basic input and a single activation button, ensuring quick adoption and fewer errors.
Yes. A detailed Bunker Transfer Report (PDF) is automatically created, containing flow rate, density, temperature, and air content. It's stored securely for evidence.
The system provides unassailable, logged evidence of irregularities. This allows timely claims within the critical 48-hour window, instantly strengthening your dispute position.
Yes. Data is securely transferred to shore via the vessel's internet connection. Headquarters uses the reports for financial verification and operational statistics.
Yes. The Advanced system issues immediate alarms for inconsistencies and can automatically regulate back pressure or reduce flow if the delivery is non-compliant.
No. We offer turnkey installation at sea, in port, or dry dock without scheduling delays. Systems are pre-configured for fast, low-impact deployment.
Maintenance is minimal as the equipment has no moving parts. Routine calibration and our 24/7 service access ensure maximum system uptime and reliability.
The system is proven on more than 50 vessels worldwide, with a six-year track record of successful, reliable operation and fraud prevention across the global fleet.
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