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Improved Cylinder Lubricator : Table 1 Conventional Cylinder Lubrication Arrangement
Improved Cylinder Lubricator : Table 1 Conventional Cylinder Lubrication Arrangement
* Translated from Journal of the JIME Vol. 37, No. 2 (Manuscript received Dec. 19, 2001)
** Mitsui Engineering & Shipbuilding Co., Ltd. (3-1-1 Tama, Tamano City, Okayama)
1.
Introduction
Cylinder lubrication for large crosshead engine is given by pressure lubrication of cylinder oil
through oil quills to cylinder liner.
lubrication of ordinary trunk piston engine which is lubricated by splashing the system oil or
spraying the oil from nozzle.
Therefore, a large crosshead engine has an exclusive-use lubricator unit for supplying cylinder oil.
A common practice for that type of lubrication is to provide a pump shown in Table 1.
That type of
Type
Drive
Lubrication frequency
Cylinder oil grade
Plunger Pump.
Mechanically jointed to engine or
motor driven.
Every revolution or random.
SAE#50
system, and there are not many reliable field experiences and test data.
In this situation, two kinds of new cylinder lubrication systems were tested in recent years, and some
field data suggest that the reduction of cylinder oil consumption rate has been acquired without any
degradation of cylinder sliding performance. It contributes significantly to the reduction of the
quantity of supplied cylinder oil gives significant contribution to the economy of large engines. For
example, if the consumption of lubricating oil in an engine operating at 30,000 PS for 8,000 hours a
year is reduced by 0.4 g/PS/h, the annual saving of the lubricating oil becomes 100 kl.
The saving
accounts for about US$ 100 thousand a year (at 1 $/liter of lubricating oil price).
The paper describes these new cylinder lubrication systems which are expected to offer large
economic merit, and gives result of analysis on the difference from conventional cylinder lubrication
system.
2.
2.1
It is clear that the conventional cylinder lubrication system is still an effective one because there are
not increasing number of defects in
cylinder parts.
type
engine,
the
For a
injection
adjusting
the
oiling
rate.
Even when the cylinder oil is ejected from the lubricator unit, the oil is not immediately fed into the
cylinder.
The reasons of the phenomenon are the following (in an order beginning from most
effective reason.)
oiling pipe cannot override the pressure of cylinder even by the ejection from the lubricator.
The
smaller ratio of the ejection volume to the capacity of oiling pipe, more delay of the supply from the
oiling pipe into the cylinder.
2)
Viscosity resistance
The viscosity resistance in the pipeline generates a pressure gradient, thus the pressure of injected oil
is consumed by the pressure increase in the pipeline.
3)
The delay of pressure increase by the oil inertia appears because the pressure propagation speed
reaches the sound speed. In cylinder oiling, however, very little influence of the inertia on the
delay occurs because a long period is necessary until the pressure gradient in the oiling pipe
stabilizes.
2.3
Item
Unit
Revolution Speed
rpm
94
Output
kW/cyl.
4900
Output
PS/cyl.
6670
mm
5.5
mm
4000
conducted.
calculation conditions.
Value
mm3
95033
Mpa
1000
MPa
0.2
MPa
0.527
mm2/s
400
Kinematic Viscosity
These
Density of Oil
kg/mm3 0.000942
g/kW/h
1.39
g/PS/h
1.02
Calculation Interval
Crank-deg
0.5
small and that the flow is a long time phenomenon which does not need the analysis of unsteady
state flow.
Figure 2 shows the calculation result under the condition of Table 2 (standard condition).
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Cylinder Pressure MPa
14
12
10
8
6
4
2
0
60
90
120
150
Crank AngleA-TDC
Figure 2 Calculation Result of Cylinder Lubrication Standard
Condition (1.39 g/kW/h : 1.02 g/PS/h)
180
Both the internal pressure of cylinder and the pressure at oil quill were the observed values.
The
cylinder lubricator unit assumed that the cylinder oil is fed to the oiling pipe at a constant feed rate.
The crank angle is expressed by the angle from BDC.
passes through the oil quill (131 in this example), the oil quill is exposed to the pressure of the
portion beneath the piston ring.
decreases stepwise.
From the first piston ring to the fourth piston ring, the pressure
This indicates that the rings successively pass through the oil quill.
With the supply of oil from the cylinder lubricator unit, the internal pressure of the oiling pipe
increases.
However, the oil does not enter the cylinder unless the following condition is
established:
Internal pressure of oiling pipe > Pressure at oil quill + Pressure difference at non-return valve
According to the example, at the crank angle 130 when the lubricator unit completed the supply of
cylinder oil, the internal pressure of oiling pipe does not satisfy the above-given condition. As a
result, the oil cannot be supplied to the cylinder.
At the crank angle 131 when the first piston ring passed through the oil quill, the pressure at oil
quill begins to decrease, then the oil begins to enter the cylinder.
supplied oil volume increases.
After the fourth ring passed, the supply of cylinder oil continues
Under the above-given condition, before the piston ring passes through the oil quill, the cylinder oil
fed above the piston ring is zero, and 38% of the cylinder oil is supplied between piston rings and
62% is supplied to the portion beneath the piston ring.
The case described above is for a cylinder oiling rate of 1.39 g/kW/h (1.02 g/PS/h).
cylinder oiling rate increases, the supply state becomes the one given in Figure 3.
When the
That is, the
percentage of oil supplied to the portion above the piston ring (before piston ring passes) increases,
the percentage of oil supplied to the portion between the piston rings does not change significantly,
and the percentage of oil supplied to the portion beneath the piston ring (after piston ring passed)
decreases.
16
14
12
10
8
6
4
2
0
60
90
120
150
180
Crank AngleA-TDC
Figure 3 Calculation Result of Cylinder Lubrication Large
Consumption (2.04 g/kW/h : 1.51 g/PS/h)
Inversely, if the cylinder oiling rate decreases, the situation becomes as given in Figure 4. That is, the
oiling timing delays to decrease the percentage of oil supplied to the first piston ring, and increase
the percentage of oil supplied to the second and succeeding piston rings.
16
Cylinder Pressure MPa
14
12
10
8
6
4
2
0
60
90
120
150
Crank AngleA-TDC
180
Lubrication
Type
Oil Consumption
Rate
Oil
Viscosity
Pipe
Length
Pipe
Diameter
g/kW/h g/PS/h
cSt
mm
Above
Higher Consumption
Conventional
2.05
1.51
400
5.5
17
34
49
Lower Consumption
Conventional
0.97
0.71
400
5.5
33
67
Standard
Conventional
1.39
1.02
400
5.5
38
62
High Viscosity
Conventional
1.39
1.02
800
5.5
21
79
Long Pipe
Conventional
1.39
1.02
400
5.5
94
Short Pipe
Conventional
1.39
1.02
400
7.7
31
69
Calculation was also given to the cases of high viscosity of cylinder oil, of large diameter of oiling
pipe, and of long oiling pipe.
pipe capacity increases and the viscosity resistance increases, thus the delay in cylinder lubrication
increases.
For the large diameter oiling pipe, the oiling response becomes favorable, and swift
oiling pipe, however, increases the capacity of the oiling pipe to fail in increase of internal pressure
of the oiling pipe, thus, the oiling does not occur immediately after the first ring passed through the
oil quill, and the oil enters the cylinder only after the second ring passed to decrease the pressure.
As described above, according to the conventional lubricator unit, the oil is difficult to enter the
portion above the piston ring, and the oil is supplied by about one third of the volume between the
piston rings, and balance of the oil is supplied beneath the piston ring.
3.
3.1
The oil fed to the portion above the piston ring is wiped
up by the piston ring to reach the upper portion of the cylinder, and is left at the top dead center, then
is vaporized and degraded in a high temperature atmosphere.
portion beneath the piston ring is wiped down by the piston ring, and a part of the fed oil may be
dropped to drain. Although not all the fed oil is workless, (if so, the engine will be seized), the oil
which was fed above or beneath the piston ring may not significantly contribute to the lubrication.
On the other hand, the oil fed to the portion between the piston rings should be held between the
rings to keep the function for a long period.
Based on the above-described concept, a new lubrication system was derived to supply maximum
volume of oil between the piston rings.
The high speed lubricator supplies more oil between the piston rings than conventional lubricator by
the lubrication system given below.
(1)
(2)
Large volume of oil is charged to the oiling pipe at a stroke, thus sufficiently increasing the
The oil is supplied at a correct timing, within a short time, and overriding the internal pressure
of cylinder.
A single lubricator unit has five or six plungers, which plungers are driven by a single hydraulic
piston.
If every cylinder has seven or more lubrication openings, two of the lubricator units are
installed.
cylinder oil.
The timing for initiate the oiling action is immediately before the first piston ring passes through the
oil quill.
Within a short period until the fourth ring passes, the oil is fed to the cylinder as large
volume as possible.
The
That is, the oil is sprayed along the cylinder wall, or in the
supply is given at the piston passing time so that even a straight nozzle can feed oil to the piston ring
and to the ring land.
However, at priming and in timer control mode in case of failing in the control
computer, the piston is not necessarily comes the oil quill, and the oil may be injected in air.
Therefore, the design is given so as the ejected oil to reach the cylinder wall even when the piston
does not reach the oil quill.
3.2
Figure 8 shows the result of model calculation for the high speed cylinder lubrication.
conditions of calculation are the same with those in conventional type.
The
oiling at a time, the inside diameter of the oiling pipe was enlarged. The oiling rate was set to 1.39
g/kW/h, or the standard condition described above.
revolutions, and the injection amount was the sum of the four revolutions.
16
70
14
50
12
10
40
8
30
6
20
Pressure MPa
60
10
0
60
90
120
150
Crank Angle-
180
Lubrication
Type
Oil Consumption
Oil
Rate
Viscosity
g/kW/h g/PS/h
Pipe
Length
Pipe
Diameter
cSt
mm
Above
Standard
Conventional
1.39
1.02
400
5.5
38
62
Standard
High Speed
1.39
1.02
400
7.7
71
27
High Viscosity
High Speed
1.39
1.02
800
7.7
52
48
Long Pipe
High Speed
1.39
1.02
400
7.7
21
79
conventional type, the percentage of fed oil between the piston rings increased.
The above-given analytical results suggest that the high speed cylinder lubrication supplies larger
volume of oil between the piston rings.
3.3
Reliability of system
Different from conventional mechanical system, the high speed lubrication system is controlled by
an electronics circuit having a computer.
10
the computer, the system can continue the lubrication by automatic functioning of a backup
electronics circuit.
The solenoid valves are general use type hydraulic control service so that they have high reliability
and durability, and no failure has occurred in field services.
from the use of clean oil and the short magnetization period of coil to reduce the heat generation thus
reducing the degradation of coil.
3.4
The simplest control method is the method of proportional to rotational speed, which is the
conventional method.
control.
There are, however, various control modes utilizing the merit of electronics
Control linking with torque, load, load variations, hydrographic conditions, etc. may be
3.5
Economy
Compared with conventional lubricator unit, the new lubricator unit has an electronics control
section and a hydraulics source, which increase the cost.
has advantages of simple structure, absence of driving shaft, and versatility in installation space.
Since the mechanical section has common parts independent of apparatus classes, the mass
production in the future should decrease the cost.
adoption of the new lubricator unit, the increased initial cost will be fully compensated.
3.7
Maintenance
Since the working environment is clean, the lubricator unit is expected to serve for almost unlimited
period, similar with the conventional unit.
3.8
3.8.1
Case 1 of Application
11
to
cylinder
12K80MC-GI-S engine.
of
The
The
The
standard
was
oiling
rate
The
high
speed
Figure 10 shows
2.5
2.0
1.5
O ct 2001
1.0
0.5
0.0
0
1000
2000
3000
4000
12
Figure 11 shows the observed values of oiling pressure on applying the high speed lubricator unit.
The internal pressure of oiling pipe increased at the timing of passing the piston ring, which shows
that the oiling was done between the piston rings.
3.8.1
Case 2 of Application
Figure 12 shows the state that high speed cylinder lubrication was applied to the 6S70MC engine.
Figure 13 shows the total system.
removed, and the piping was given to allow using both units.
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rate was increased owing to the supply of poor quality fuel. After that, however, the oiling rate was
decreased to current level of 1.22 g/kW/h (0.9 g/PS/h), and the operation has been proceeding in a
favorable state.
4.0
3.5
3.0
2.5
O ct 2001
2.0
1.5
1.0
0.5
0.0
0
2000
4000
6000
8000
10000
Figure 15 shows the state of piston ring. The condition of No. 1 and No. 2 cylinders equipped with
the high speed lubricator unit are favorable similar with other cylinders.
The above-described on-board tests showed that the high speed cylinder lubrication is expected to
reduce the cylinder oiling rate without degrading the cylinder condition.
14
4.
Different from the high speed cylinder lubrication, the SIP cylinder lubrication aims to form thin and
uniform oil film by spraying cylinder oil against the wall of cylinder liner.[1]
The term SIP is the abbreviation of Swirl Injection Principle, which name was presented by Mr.
Dragsted of A.P.Moller.
It was told that Mr. Dragsted hit on the principle when he saw that the mist
of sprayed antiseptic solution was blown by the wind and was attached to trees.
As illustrated in Figure 16, the lubricating oil is sprayed from oiling nozzle, and the sprayed droplets
are carried by the sweeping swirl air to spread over the upper slant area. The sprayed oil covers the
wide area on the inner wall of cylinder liner.
lubricator
unit
was
For
There is
6.
Conclusion
Conventional mechanical lubricator unit supplies large volume of lubricating oil to the portion
beneath the piston ring, and the oil is doubtful in efficient contribution to the cylinder lubrication.
To improve the disadvantage, the high speed and high pressure lubrication system (Alpha system)
and the SIP lubrication system have been developed. Both systems show favorable performance
15
the lubricating oil which was wasted in cylinder, thus reducing the total amount of lubricating oil
supply.
7.
Acknowledgement
The author would like to express appreciation to Mr. Tetsugo Fukuda of G.I.D Co., Ltd. and to Mr.
Takeshi Takemoto of Daishin Ship Co., Ltd. for their cooperation to on-board testing.
REFERENCES
[1] Jensen, T., "Swirl Injection Lubrication Low Cylinder Oil Consumption without Sacrificing Wear
Rates", Journal of JIME, 37-2(2002)125
Masaki Tanaka
who engage in marine transportation play a role of supporting and driving the future world with
proud.
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