2009/04/01© MAN Diesel [current topic] < 1 >
Cylinder lubrication
Peter Rytter JensenHead of Retrofit ProductsPrimeServ Copenhagen
2009/04/01© MAN Diesel [current topic] < 2>Japan, autumn 2009, by Henrik Rolsted
Cylinder Lubrication
Purpose of cylinder oil:
Lubrication: build up oil film between piston rings and cylinder liner
Cleaning: additive treat contains detergency agent
Neutralisation: Bunker oils contain varying levels of sulphur
-
-
-
2009/04/01© MAN Diesel [current topic] < 3>Japan, autumn 2009, by Henrik Rolsted
Cylinder Lubrication
Purpose of cylinder oil:
Lubrication: build up oil film between piston rings and cylinder liner
Cleaning: additive treat contains detergency agent
Neutralisation: Bunker oils contain varying levels of sulphur
-
-
-
Cylinder oil requirements:
Stability to heat
Detergency independent of BN
Varying BN
Easy feed rate adjustment
2009/04/01© MAN Diesel [current topic] < 4>Japan, autumn 2009, by Henrik Rolsted
Cylinder Lubrication
Cylinder oil requirements:
Stability to heat
Detergency independent of BN
Varying BN
Easy feed rate adjustment
-
-
-
-
2009/04/01© MAN Diesel [current topic]
Cylinder Condition of LargeTwo-Stroke Engines
Medium sulphur fuel High sulphur fuel (above 4%)
Feed rate
0.15M
in.f
eed
rate
Low sulphur fuel (below 2%)
Line
r wea
r rat
e [m
m/1
000h
]
Max
.fe
edra
te
Bas
ic se
tting
0.070.01
L/72666-3.0/0602 (2300/HRJ)
2009/04/01© MAN Diesel [current topic]
Alpha ACC
Optimised (reduced) side andtop-clearances introducedbased on good experiencewith the MC-CompactenginesOptimal ‘lemon-shape’will give a minimum oil filmthickness increase of 30-40%
L/74401-4.0/0802 (2410 /SBJ)
Sulphur %
Cylinder oil dosage (g/bhph)
0 1 2 3 4 5
1.25
1.00
0.75
0.50
0.25
0
2009/04/01© MAN Diesel [current topic] < 9>Japan, autumn 2009, by Henrik Rolsted
Liner WearASTRO CYGNUS 6S90MC-C
899.00
900.00
901.00
902.00
903.00
904.00
905.00
906.00
0 5000 10000 15000 20000 25000 30000 35000 40000 45000 50000
Engine Hours
Max
Lin
er D
iam
eter
(mm
)
0.1 / 1000 Hours (mm)Cyl No. 1ACyl No. 2ACyl No. 3ACyl No. 4ACyl No. 5ACyl No. 6A
0.05mm/1000hAC
C 0
.34
g/kW
h x
S%
AC
C 0
.20
g/kW
h x
S%
AC
C 0
.23
g/kW
h x
S%
AC
C 0
.26
g/kW
h x
S%
AC
C 0
.29
g/kW
h x
S%
Cylinder Condition, New lube guidelines
2009/04/01© MAN Diesel [current topic] < 10>Japan, autumn 2009, by Henrik Rolsted
Cylinder Lubrication, New guidelines and experience
2009/04/01© MAN Diesel [current topic] < 11>Japan, autumn 2009, by Henrik Rolsted
Cylinder Lubrication, New guidelines and experience
2009/04/01© MAN Diesel [current topic] < 12>Japan, autumn 2009, by Henrik Rolsted
Cylinder Condition, New lube guidelines
2009/04/01© MAN Diesel [current topic] < 13>
0.82
1.36
1.63
1.22
1.50
1.090.99
0.70 0.65
0
0.2
0.4
0.6
0.8
1
1.2
1.4
1.6
1.8
spec
. con
sum
p. g
/kW
h at
MC
R
L-MC M
k I 15
barK/L-M
C MK III
17 bar
S-MC M
K III-V
I 18 b
ar
K/L-MC, S
L 385
S-MC, S
L 385
K/L/S Alpha l
ub
Alpha ACC
ACC 0.26
x S%, 21 b
ar
New SL 0.
20
Cylinder Oil feed rate history on the MC/E engines 1982 to 2009
Cylinder Condition, New lube guidelines
Hamburg. May 2009, by Henrik Rolsted
SULPHUR
0.46%
3.79%3.03%
7.68%
22.39%
27.09%
22.02%
11.97%
1.39%0.19%
0.00%
5.00%
10.00%
15.00%
20.00%
25.00%
30.00%
<0.50 0.50 - 0.99 1.00 - 1.49 1.50 - 1.99 2.00 - 2.49 2.50 - 2.99 3.00 - 3.49 3.50 - 3.99 4.00 - 4.49 4.50 - 4.99
Sulphur Content
% of Deliveries
0.00
0.20
0.40
0.60
0.80
1.00
1.20
0 0.5 1 1.5 2 2.5 3 3.5 4 4.5 5Abs
olut
e do
sage
s (g
/kW
h)
Sulphur %
New ACC Cylinder
ACC factor 0.20 g/kWh
Flat rate at lower sulphur then 3%
X
2009/04/01© MAN Diesel [current topic] < 14>Japan, autumn 2009, by Henrik Rolsted
Cylinder Condition, New lube guidelines
2009/04/01© MAN Diesel [current topic] < 15>
0.000.100.200.300.400.500.600.700.800.901.001.101.201.301.401.501.601.70
0 0.5 1 1.5 2 2.5 3 3.5 4 4.5 5
Sulphur %
Abs
olut
e do
sage
(g/k
Wh)
ACC factor 0.34 g/kWh x S% for Low top land Engines
ACC factor 0.20 g/kWh x S% for High top land Engines
Lower limit set for hydrodynamic reasons
Degree of over additivation
Japan, autumn 2009, by Henrik Rolsted
Cylinder Lubrication, latest experience
2009/04/01© MAN Diesel [current topic]
0
100,000
200,000
300,000
400,000
500,000
600,000
700,000
Typical feed-rate(mechanical lubricator):
1.2 g/bhph, rpm-control
Basic feed-rate(mechanical lubricator):0.9 g/bhph, rpm-control
Basic feed-rate(Alpha lubricator):
0.8 g/bhph, mep-control
Alpha ACC(Alpha lubricator):0.25 g/bhph/S%
Yearly cylinder oil expense (USD)Cylinder oil price: 1 USD/kg
Yearly operating hours: 7,100
Alpha ACC,12K90MC, Typical Operating Profile
L/74406-3.0/0802 (2410 /SBJ)
Yearly Saving:
340,000 USD
2009/04/01© MAN Diesel [current topic] < 17>
$15,564,830; 85%
$200,000; 1%
$500,000; 3%
$1,500,000; 8% $560,000
Fuel CostCylinder Lube costCrew costEngine maintenanceShip maintenance
Cylinder Condition, New lube guidelines
Operational cost for a 12K98ME-C7
Japan, autumn 2009, by Henrik Rolsted
16% saving is equal to $90,000 per year
2009/04/01© MAN Diesel [current topic] < 18>
$15,564,830; 85%
$200,000; 1%
$500,000; 3%
$1,500,000; 8% $560,000
Fuel CostCylinder Lube costCrew costEngine maintenanceShip maintenance
Cylinder Condition, New lube guidelines
Operational cost for a 12K98ME-C7
Japan, autumn 2009, by Henrik Rolsted
30% saving is equal to $170,000 per year
2009/04/01© MAN Diesel [current topic]
Alpha ACC
Oil film thickness in the highpressure areas of the bearings was not optimal
0
10
20
30
40
50
60
70
80
90
100
0 10 20 30 40 50 60 70 80 90 100
Load (%)
Part load dosage (% of full load dosage)
rpm proportional (%)mep proportional (%)Load proportional (%)
Typical case: 74,640 bhp x 24hx 1.2g/bhph x 0.91 = 1,956 kg/24h
Alpha ACC: 74,640 bhp x 24hx 0.75g/bhph x 0.75 = 1,008 kg/24h
Example,12K90MC:Load (%): 75S %: 3.0
L/74402-6.0/0802 (2410 /SBJ)
2009/04/01© MAN Diesel [current topic]
Alpha ACC
00.10.20.30.40.50.60.70.80.91
0 1,000 2,000 3,000 4,000 5,000 6,000 7,000 8,000 9,000 10,000 11,000
Liner wear (mm/1000h)
00.20.40.60.81
1.21.41.6 Liner wear (mm)
0.48 mm/1000h 0.13 mm/1000h
0.00 mm/1000h0.00 mm/1000h0.06 mm/1000h0.04 mm/1000h
0.21 mm/1000h
*
*: Judgement made based on fe-content in drain oil samples
From detailed wear-study of 12K90MC engine equipped with mechanical lubricator
L/74407-5.0/0802 (2410 /SBJ)
2009/04/01© MAN Diesel [current topic]
Alpha ACC
Oil film thickness in the highpressure areas of the bearings was not optimal
Optimised (reduced) side andtop-clearances introducedbased on good experiencewith the MC-CompactenginesOptimal ‘lemon-shape’will give a minimum oil filmthickness increase of 30-40%
Mechanical Lubricator, rpm-proportional control
Alpha adaptive control
L/74408-7.0/0802 (2410 /SBJ)
0 1,000 2,000 3,000 4,000 5,000 6,000 7,000 8,000 9,000 10,000 11,000
0.9
0.8
0.7
0.6
0.5
0.4
0.3
0.2
0.1
0
Liner wear (mm/1000h)
Running hours
2009/04/01© MAN Diesel [current topic]
40
50
60
70
80
90
100load (%)
1,51,71,92,12,32,52,72,93,1
Sulphur (%)Load Sulphur content
100015002000250030003500400045005000
5-dec-01
25-dec-01
14-jan-02
3-feb-02
23-feb-02
15-mar-02
4-apr-02
24-apr-02
Sulphur (kg/24h)
Alpha ACC12K90MC, Typical Operating Profile
L/74429-1.0/0802 (2410 /SBJ)
2009/04/01© MAN Diesel [current topic]
0
500
1000
1500
2000
2500
5-dec-01 25-dec01 14-jan-02 3-feb-02 23-feb-02 15-mar-02 4-apr-02 24-apr-02
Daily consumption (litre/24h)
Basic feed-rate (Alpha lubricator System), 0.8 g/bhph, mep-control
Typical feed-rate (mechanical lubricator), 1.2 g/bhph, rpm-control
Basic feed-rate (mechanical lubricator, 0.9 g/bhph, rpm-control
Alpha ACC: 0.25 g/bhph/S%
Alpha ACC12K90MC, Typical Operating Profile
L/74430-1.0/0802 (2410 /SBJ)
2009/04/01© MAN Diesel [current topic]
Retrofit Alpha
L/73614-2.1/0403 (4100/PYJ)
1. Pump station
2. Alpha Lubricator
3. Conventional lubricator
4. T-piece
5. ALCU (Computer)
6. Non-return valves
2009/04/01© MAN Diesel [current topic]
HMI Panel
L/74403-8.0/0802 (2410 /SBJ)
0 100%
Fuel index
Oil pressure
Engine speed
0 100%
0 100%
Oil pressurelow
rpm
%
bar
Index failure
oC
deg
min
Mark/trigfailureFedbackfailureCommonalarm
2009/04/01© MAN Diesel [current topic] < 34>34
Cylinder Lubrication, latest experience
The experience with the newest generation of engines with high topland and Oros Combustion Chamber is a very low corrosive level and consequential very low- to nearly zero liner wear.
This ensure very long component life time and long TBO.
Further the need for cylinder oil is very low compared to previous engine designs.
The disadvantages with very low liner wear is the risk of bore polish and a lower scuffing resistance, especially at low sulphur running.
2009/04/01© MAN Diesel [current topic] < 35>Japan, autumn 2009, Presented by Henrik Rolsted
Testing flat rate at 0.50 g/kWh abs.
•8S60MC Car-carryer, 45,191 running hours
•At 15000 running hours: Cyl.inder Lubricator fitted with 3.5 mm pistons instead of 6 mm
•High topland piston
•Alu-coated CPR piston rings
•Slide fuel valve
•Low cyl. oil dosages 0.55 g/kWh the last 4019h
•Cylinder oil Taro special 70
•Piston (number 1) never pulled (42,773 ring hours!
•Now running 0.50 g/kWh flat rate the last 3,000 hours
Cylinder Lubrication, latest experience