Lubrication in Four-Stroke Marine Diesel Engines

E. Hlede L.Davia

Attrito, Usura e Lubrificazione in Campo Navale Napoli, 13 Maggio 2010 XI Convegno di Tribologia

Wrtsil

Lubrication in 4-Stroke Marine Diesel Engines / E Hlede - L Davia

WRTSIL CORPORATION

Table of contents

Introduction to Wrtsil Introduction to 4-stroke Diesel engines Diesel Engine Lubrication Future Prospectives

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Lubrication in 4-Stroke Marine Diesel Engines / E Hlede - L Davia

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This is Wrtsil

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POWER PLANTS

SERVICES

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Lubrication in 4-Stroke Marine Diesel Engines / E Hlede - L Davia

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Lubrication in 4-Stroke Marine Diesel Engines / E Hlede - L Davia

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Lubrication in 4-Stroke Marine Diesel Engines / E Hlede - L Davia

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WE SUPPORT OUR CUSTOMERS THROUGHOUT THE LIFE-CYCLE OF THEIR INSTALLATIONS BY OPTIMISING EFFICIENCY AND PERFORMANCE

We provide the broadest portfolio and best services in the industry for both ship power and power plants. We offer expertise, proximity and responsiveness for all customers regardless of their equipment make in the most environmentally sound way.

Wrtsil

Lubrication in 4-Stroke Marine Diesel Engines / E Hlede - L Davia

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Wrtsil Italia Engines

W26 W38B W46 W46F W50DF

from

To

1,860

7,200

kW kW kW kW kW kW

4,350 11,600 5,850 20,790 7,500 20,000 5,500 17,100

W64 12,060 17,200

W26

W38

W46

W46F

50DF

W64

Wrtsil

Lubrication in 4-Stroke Marine Diesel Engines / E Hlede - L Davia

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Wrtsil R&D footprint

Trondheim, Norway Stord, Norway
Electrical & Automation systems Frequency converters

Vaasa, Finland
W20; W32/32DF/34SG, Ecotech

Rubbestadneset, Norway
CPP, Gears

Turku, Finland
Ecotech

Espoo, Finland
Fuel cells, Ecotech

Drunen, The Netherlands

CPP, FPP, Thrusters

Havant, UK; Slough, UK

Face Seals, Synthetic Bearings

Winterthur, Switzerland
2-stroke: RT-flex, RTA

Trieste, Italy
W26, W38, W46, W46F, W50DF, W64

Toyama, Japan
Rubber Seals & Bearings

Bermeo, Spain
W34SG, W50DF

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Lubrication in 4-Stroke Marine Diesel Engines / E Hlede - L Davia

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Introduction to 4-stroke Diesel engines

4-stroke engine (4-cycle engine)

This is an engine in which the pistons complete their power stroke every second crankshaft revolution. The four strokes are: intake, compression, power and exhaust. (also called: inlet, compression, combustion and outlet). The 4-stroke cycle is so called because it takes 4 strokes of the piston to complete the processes needed to convert the energy in the fuel into work. Because the engine is reciprocating, this means that the piston must move up and down the cylinder twice, and therefore the crankshaft must revolve twice.

Wrtsil

Lubrication in 4-Stroke Marine Diesel Engines / E Hlede - L Davia

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Introduction to 4-stroke Diesel engines

Diesel engine operating principle (4-stroke)

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Lubrication in 4-Stroke Marine Diesel Engines / E Hlede - L Davia

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Introduction to 4-stroke Diesel engines

Division of engines according to speed

Low speed engine (Slow speed engine) An engine broadly defined as running at speeds below 300 rpm. Low speed engines are also called "slow speed" engines. Low speed engines are typically two stroke engines. Medium speed engine An engine broadly defined as running at speeds of 3001200 rpm. High speed engine An engine broadly defined as running at speeds above 1200 rpm. Remarks! These speed categories (low, medium, and high speed) are general "rules of thumb" and not officially defined by any regulatory body

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Wrtsil

Lubrication in 4-Stroke Marine Diesel Engines / E Hlede - L Davia

WRTSIL CORPORATION

Diesel Engine Lubrication

Function of lubricating oil

Lubricating oil is an integrated engine component Main function of lubricating oil is to maintain power producing efficiency and ability by

lubrication and sealing cooling cleanliness corrosion protection

while staying in good condition

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Wrtsil

Lubrication in 4-Stroke Marine Diesel Engines / E Hlede - L Davia

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Influence of lubricating oil properties on engine components

Fuel injection pump: Fuel / lubricating oil compatibility

Piston cooling gallery, ring groove area, Piston skirt, cylinder liner: High temperature detergency Thermal stability Alkalinity Antiwear Oxidation stability Cams and rollers: Antiwear Extreme pressure Cold engine components: Low temperature detergency Corrosion resistance Cooler Pump

Separator

Bearings: Corrosion resistance Oxidation stability Crankcase: Water resistance Foaming resistance Dispersancy Detergency

Filter

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Wrtsil

Lubrication in 4-Stroke Marine Diesel Engines / E Hlede - L Davia

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Function of lubricating oil

Lubrication and sealing Cooling Cleanliness Corrosion protection

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Wrtsil

Lubrication in 4-Stroke Marine Diesel Engines / E Hlede - L Davia

WRTSIL CORPORATION

Function of lubricating oil

Lubrication and sealing Cooling Cleanliness Corrosion protection

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Wrtsil

Lubrication in 4-Stroke Marine Diesel Engines / E Hlede - L Davia

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Types of lubrication
Load Movement Bearing Oil out Oil in Hydrodynamic lubrication Hydrostatic lubrication Oil out Load

Boundary lubrication

Metal to metal contact

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Wrtsil

Lubrication in 4-Stroke Marine Diesel Engines / E Hlede - L Davia

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Properties related to lubrication

Measure of fluids resistance to flow Viscosity increase indicates: oil oxidation presence of soot & combustion originated material HFO leakage to lube oil Viscosity decrease indicates LFO leakage to lube oil Wrtsils limit: -20% / +25% 5000 change @ 100 C -25% / +45% change @ 40 C

Viscosity:
170

160

150

140

130

120 0 1000 2000

VISCOSITY AT 40 C

3000
VISCOSITY AT 100 C

4000

OIL SERVICE HOURS (h)

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Wrtsil

Lubrication in 4-Stroke Marine Diesel Engines / E Hlede - L Davia

WRTSIL CORPORATION

Function of lubricating oil

Lubrication and sealing Cooling Cleanliness Corrosion protection

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Wrtsil

Lubrication in 4-Stroke Marine Diesel Engines / E Hlede - L Davia

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Cooling of engine components

Bearings Pistons

Example of average oil temperature in piston

120

110 TEMPERATURE (C) OIL TEMP ERATURE OUT OF PISTON 100

90

80 OIL TEMP ERATURE INTO PISTON 70 0 25 50 75 100 125 ENGINE LOAD (% )

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Wrtsil

Lubrication in 4-Stroke Marine Diesel Engines / E Hlede - L Davia

WRTSIL CORPORATION

Function of lubricating oil

Lubrication and sealing Cooling Cleanliness Corrosion protection

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Wrtsil

Lubrication in 4-Stroke Marine Diesel Engines / E Hlede - L Davia

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Engine cleanliness

The lubricant must remove sludge to prevent deposit formation

Sludge originates from: water fuel solid residues Deposits and lacquer combustion products from fuel combustion products from lubricant lubricant / fuel that has oxidised lubricant / fuel that has cracked lubricant / fuel that has polymerised Fuel / lubricating oil compatibility is important

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Wrtsil

Lubrication in 4-Stroke Marine Diesel Engines / E Hlede - L Davia

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Piston cooling gallery cleanliness

Influence of piston cooling gallery deposit thickness on piston top temperature
250

200

150

Limits: W32, 38, 46, 64 - aver. 300 m - max. 400 m W20, W26 - aver. 200 m - max. 300 m

100

50

0 0 200 400 600 800 1000 DEPOSIT THICKNESS [ m]

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Lubrication in 4-Stroke Marine Diesel Engines / E Hlede - L Davia

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Properties related to cleanliness

Insolubles:

1.0

0.8

0.6

0.4

0.2

0.0 0 1000 2000 3000 OIL SERVICE HOURS (h) 4000

Describes the amount of solid contaminants present in lube oil Consists of soot, dust and wear debris as well as of oxidation products derived from fuel / lube oil Several analysis methods exists having an influence on exact analysed value Wrtsils limit: max. 2.0 % m/m measured with 5000 ASTM D 893b method

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Wrtsil

Lubrication in 4-Stroke Marine Diesel Engines / E Hlede - L Davia

WRTSIL CORPORATION

Function of lubricating oil

Lubrication and sealing Cooling Cleanliness Corrosion protection

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Wrtsil

Lubrication in 4-Stroke Marine Diesel Engines / E Hlede - L Davia

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Properties related to corrosion protection

Describes the available alkali reserve in lube oil BN is decreasing when acid sulphur and nitrogen originated combustion residues are reacting with alkali reserve SLOC and fuel S content are the main factors influencing on BN depletion rate Wrtsils limit: min. 20 mg KOH/g on HFO operation max. 50% 5000 depletion on LFO operation

Base Number (BN):

55

50

45

40

35

30

25

20 0 1000 2000 3000 4000 OIL SERVICE HOURS (h)

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Wrtsil

Lubrication in 4-Stroke Marine Diesel Engines / E Hlede - L Davia

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Example of wear rates

Corrosive wear increases at higher fuel sulphur levels Corrosive wear decreases dramatically at higher BN

Wear, mm/10000 h

High sulphur fuel

Low sulphur fuel

10

15

20

25

30

BN, mg KOH/g

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Wrtsil

Lubrication in 4-Stroke Marine Diesel Engines / E Hlede - L Davia

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Reasons for oil change, HFO operation

100

80

75

75

60

40

20 20 5 0 Viscosity Insolubles 1 Other

20

Base Number Viscosity 2 With anti-polishing ring

Other

Without anti-polishing ring

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Wrtsil

Lubrication in 4-Stroke Marine Diesel Engines / E Hlede - L Davia

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Base number depletion

40

Fuel sulphur No antipolishing ring Dry sump

S = 1.75 % m/m SLOC = 1.2 g/kWh LV = 1.5 l/kW

Base number (mg KOH/g)

30
S = 3.5 % m/m SLOC = 1.2 g/kWh LV = 1.5 l/kW S = 3.5 % m/m SLOC = 0.4 g/kWh LV = 1.5 l/kW S = 3.5 % m/m SLOC = 0.4 g/kWh LV = 0.75 l/kW

20
Change interval

Condemning limit

10

1000

2000

3000

4000 5000 6000 Running hours (h)

7000

8000

9000

10000

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Lubrication in 4-Stroke Marine Diesel Engines / E Hlede - L Davia

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Properties related to wear

Iron (Fe):

50

40

30

20

10

Indicates mainly wear of cylinder liners and pistons Fresh oil can contain iron up to 10 ppm originating from tanks and pipes Typical analysis accuracy 10%
0 1000 2000 3000 4000 5000

OIL SERVICE HOURS (h)

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Wrtsil

Lubrication in 4-Stroke Marine Diesel Engines / E Hlede - L Davia

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Summary of main lube oil characteristics

PROPERTY CHANGE IN PROPERTY Low base number High insolubles content High viscosity IMPACT ON ENGINE OPERATION Corrosive wear Liner, piston ring groove Dirty engine Deposit formation Wear of bearings etc. More friction Reduced cooling Thinner oil film Metal - metal contact Deterioration of oil film Bearing damage CONDEMNING LIMIT (HFO OPERATION) min. 20 mg KOH/g max. 2.0 % m/m in n-pentane 45% increase at 40 C 25% increase at 100 C 25% decrease at 40 C 20% decrease at 100 C max. 0.3 % V/V

Base number Insolubles

Viscosity

Low viscosity

Water content

High water content

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Lubrication in 4-Stroke Marine Diesel Engines / E Hlede - L Davia

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FUTURE PROSPECTS IN ENGINE LUBRICATION

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Wrtsil

Lubrication in 4-Stroke Marine Diesel Engines / E Hlede - L Davia

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Engine energy losses

About 10-15% of all energy supplied to an engine is lost due to friction

Other 20%

Crank train 15% Valve train 5%

Piston assembly 60%

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Lubrication in 4-Stroke Marine Diesel Engines / E Hlede - L Davia

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Solid lubricants

Low friction coefficient ( 0.4) Lattice structure arranged in layers Strong bonds between atoms within a layer and relatively weak interatomic interactions (van der Waals forces) between atoms of different layers allow the lamina to slide on one another

Low shear strenght

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Lubrication in 4-Stroke Marine Diesel Engines / E Hlede - L Davia

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Solid lubricants
9 Graphite
graphite is structurally composed of planes of polycyclic C atoms that are hexagonal in orientation. The distance of carbon atoms between planes is longer and therefore the bonding is weaker water vapour is a necessary component for graphite lubrication. The adsorption of water reduces the bonding energy between the hexagonal planes of the graphite to a lower level than the adhesion energy between a substrate and the graphite graphite is not effective in vacuum

Graphite structure
34 Wrtsil Lubrication in 4-Stroke Marine Diesel Engines / E Hlede - L Davia WRTSIL CORPORATION

Solid lubricants
9 MoS2
the most widely used form of solid film lubrication today like graphite, it has a hexagonal crystal structure with the intrinsic property of easy shear: weak atomic interaction (Van der Waals) of the sulphide anions, while covalent bonds within molybdenum are strong lubrication relies on slippage along the sulphur atoms; all the properties of the lamella structure are intrinsic effective in vacuum or dry atmosphere the temperature limitation of MoS2 at 400C is restricted by oxidation.

MoS2 structure
S Mo S S Mo S

9 WS2
Max working temperatures about 100C higher than MoS2

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Lubrication in 4-Stroke Marine Diesel Engines / E Hlede - L Davia

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Solid lubricants

9 BN, white graphite

Hexagonal Boron Nitride (h-BN, -BN, or g-BN graphitic BN) high temperature resistance, 1200C service temperature in an oxidizing atmosphere lubricant at both low and high temperatures (up to 900 C, even in oxidizing atmosphere) since the lubricity mechanism does not involve water molecules trapped between the layers, boron nitride lubricants can be used even in vacuum high thermal conductivity the cubic structure is very hard and used as an abrasive and cutting tool component

9 BaF2/CaF2

High Temperatures (effective lubricating above 400C)

9 Ag

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Lubrication in 4-Stroke Marine Diesel Engines / E Hlede - L Davia

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Self-lubricating coatings

9 Thin coatings
Physical Vapor Deposition (PVD) , Chemical Vapor Deposition (CVD), Thickness 10 m

9 Thick coatings
Air or Vacuum Plasma Spray (APS and VPS), High-velocity Oxy-fuel Spray (HVOF), Plasma Transferred Arc (PTA), ... Cermets coatings 0,1 mm thickness 15 mm

High-velocity oxyfuel process

37 Wrtsil Lubrication in 4-Stroke Marine Diesel Engines / E Hlede - L Davia WRTSIL CORPORATION

Self-lubricating coatings
Properties & Selection: Thermal stability: very important since one of the most significant uses of these materials is in high temperature applications not tolerated by other lubricants: Oxidation stability High temperature corrosion Volatility Adhesion on base material Hardness Thermal shock resistance

SEM backscattered micrograph of a NiCr(80/20)/Cr2O3-Ag-BaF2CaF2 coating Source: W. Wang. Surface and Coatings Technology 177 178 (2004) 1217
38 Wrtsil Lubrication in 4-Stroke Marine Diesel Engines / E Hlede - L Davia WRTSIL CORPORATION

Benefits in engine components

Functional coated components enabling: Use of new clean fuels (ultra low sulphur) and other new fuels (bio fuels etc.) Use of different fuels in multi-fuel engines Improve durability (especially for components running at high temperature) Better performance (NOx and CO2) Reduce oil dependence Green products

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Lubrication in 4-Stroke Marine Diesel Engines / E Hlede - L Davia

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Thank you for your attention

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