ppt0000005 [sola lettura] - unina.it · wear is the risk of bore polish and a lower scuffing...

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

-

-

-



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



Cylinder oil requirements:

Stability to heat

Detergency independent of BN

Varying BN

Easy feed rate adjustment

-

-

-

-

2009/04/01© MAN Diesel [current topic]

Over-lubricated


Alpha ACC

Cylinder wear

Cylinder oil amount

4100/CBO/200103


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)


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


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


Cylinder Lubrication, New guidelines and experience

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


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


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


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


$15,564,830; 85%

$200,000; 1%

$500,000; 3%

$1,500,000; 8% $560,000

Fuel CostCylinder Lube costCrew costEngine maintenanceShip maintenance


Operational cost for a 12K98ME-C7


16% saving is equal to $90,000 per year


$15,564,830; 85%

$200,000; 1%

$500,000; 3%

$1,500,000; 8% $560,000

Fuel CostCylinder Lube costCrew costEngine maintenanceShip maintenance


Operational cost for a 12K98ME-C7


30% saving is equal to $170,000 per year


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)


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)


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


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)


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)


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


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


CBO/4100/20020923

Lubricator


NON RETURN V/V and T-PIECE


CBO/4100/20020923

Alpha lube Control Unit (ALCU)


Retrofit

(4100/CBO/20012003)


READY TO SAVE MONEY

2009/04/01© MAN Diesel [current topic] < 34>34


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



Optimising cyl. oil feed rate


Service Experiencewith Alpha lubricated S90MC-C

L/73133-6.0/0702 (3001/UM)

Alpha Adaptive Cylinder Oil Control (Alpha ACC). The condition at 4884 h, after 1518 hours at Alpha ACC

ppt0000005 [sola lettura] - unina.it · wear is the risk of bore polish and a lower scuffing...

Documents