LUBRICANT SYSTEM OF POWER PLANTS

Part 1
 1 PURPOSE OF LUBRICATION SYSTEMS
AND REQUIREMENTS TO THEM

A lubrication system represents a set of units intended for lubrication of the

engine, heat rejection from engine units, and also the removal of solid
particles, which are formed between surfaces subjected to friction, in all
aircraft operating conditions.
Even short–term breaks in oil feeding result in the engine overheating,
destruction of its bearings, wedging of pistons, or a rotor, breakage of
connecting rods and, as a result, the engine failure.
Oil in power plants is also used as a hydraulic fluid in various devices (such
as a propeller pitch control mechanism, fuel control units, an rpm governor,
etc.).
The lubrication system consists of two sections: external and internal. The
external section is a component of the aircraft power plant.
The internal section is a component of the engine. In our course we shall
consider only the external section of a lubrication system.
 REQUIREMENTS TO LUBRICATION SYSTEMS

1. Reliable oil supply to the engine at the temperature and pressure due to
specifications, in any aircraft operation conditions.
2. Minimum power consumption in the heated oil cooling process.
3. Reliable oil filtering from mechanical impurities and gases.
4. Fast oil heating, to reduce the heating–up time of the engine.
5. Preventing oil ejection through venting and overflow of the engine settings.
6. Preventing oil overflows from the tank into the inoperative engine.
7. The minimal mass of the system.
8. The sufficient strength, vibration strength, leak resistance, and minimal
hydraulic resistance of the system elements.
9. Fire safety.
10. Maintainability (convenient access to the lubrication system for
maintenance and repair).
11. On multi–engine aircraft, each engine should have an independent
lubrication system.
12. Pipelines and units of lubrication systems should be brown color.
 2 Aviation oils

For the reliable and continuous operation of a lubrication system, oil

characteristics are very important. Operating conditions for oils in engines
are complicated and various, therefore oil specifications are characterized
by strict requirements to their physical and chemical properties.
Viscosity is one of the major characteristics of oil. If oil viscosity is
insufficient, the liquid layer of the oil cannot stay in clearances and is
extruded at heavy loadings. As a result dry friction emerges, which
increases the wear of parts.
If oil viscosity is too high, then:
– friction forces increase, which causes power losses;
– oil does non get to units with small clearances;
– increased pressure in lubrication system is required for pumping oil;
– engine start-up is complicated.
The value of oil viscosity is measured by the factors of viscosity. Just as with
fuel, there are two factors of oil viscosity: kinematic and dynamic ones. The
factor of kinematic viscosity of aviation oils lies in the range:
ν = 2,5…25 mm 2/s.
The viscosity of oil drops with the increase of temperature. In the past,
most aviation oils were made from petroleum, by acid (МК) or selective
(МС) clearing. The viscosity of such oils drops sharply with an increase
temperature. High temperature in lubrication system results in the active
vaporation and oxidation of these oils. The resulting deterioration of their
physical and chemical properties, worsens the lubrication system
operation. Now, in heat–stressed engines, synthetic oils are widely used.
They are formed on the basis of esters. The viscosity–temperature
relation for such oils is weaker. Besides, these oils have a broad range
of operation temperatures.
The density of aviation oils makes ρ = 850... 950 kg/m3.
The thermal–oxidative durability of oil is characterized by maximum
temperature at which the oil can be used. When this temperature is
exceeded oil is coked, i.e. precipitate appears in it, and a film is formed
on the greased parts. The type of oil to be used is determined by the
type of the engine.
 3 General characteristics of lubrication systems

3.1 Lubrication systems for piston engines

Lubrication systems for piston engines are the most complicated and
loaded ones. Piston engines have a big friction area. There is high
pressure on these surfaces, which increases the heat transfer in the oil.
Second feature of lubrication system of piston engines is that, oil directly
contacts with a combustion zone, which causes high oil consumption
(CP = 8...16 g/(hour⋅kw)).
To provide lubrication system operation in these conditions, oils with
viscosity 20...25 sSt at 100°C are required, for example МС–20, МК–22
(the number in the marking designates viscosity in sSt at 100°С). In
winter conditions less viscous oils are applied.
The recommended oil temperature makes 65...75°C at the input
connection of an engine, and 105...125°C at the output connection.
Delivery oil pressure lies in the range 0.5...0.8 МPа.
 3.2 Lubrication systems of (bypass) turbojets
Principal type of friction in these engines is rolling friction. Therefore power
consumption for overcoming of friction forces and quantity of transferring heat
are insignificant (85...170 J/(daN⋅min)). Pumping of oil through the engine makes
3...5 dm3/min per bearing. The consumption of oil basically is made from losses
through the breather system. It makes ≈1 g/(daN⋅hour).
In these conditions they apply oils with small viscosity (МК–6, МК–8, and also
synthetic oils).
The allowable temperature of oil makes 25...80°C at input connection, and
100...130°C at output connection. Delivery pressure of oil in turbojets lays into
the range 0.1...0.4 МPа.
3.3 Lubrication systems of turboprops
Lubrication systems of turboprops are intermediate by complexity and loadings
between lubrication systems of piston engines and turbojets.
Difference from systems of turbojets is presence of a propeller gear, which
transmits high power. Hence its pinions require a flooded lubrication.
Heat transfer into oil at turboprops (680...1400 J/(kw⋅min)) is higher, than at
turbojets, but is lower than at piston engines. Accordingly pumping of oil
(0.65...0.98 dm3/(kw⋅hour)) also takes an intermediate position.
It is not desirable to apply oils with big viscosity here. As speed of changes of
blade angle of a propeller is decreased and engine start–up is complicated.
Usually for lubrication of turboprops a mixture of oils with high and low viscosity
is used. For example, 75 % of МС-20 and 25 % of МК-8.
4 Schemes of lubrication systems. Ways of separation of air from oil

Lubrication systems are of two different types: closed (circulating) and

open. Last apply on products of single application. Systems of the closed
type are used in aviation.
The direct scheme of lubrication system The simplest scheme of lubrication
system is the direct scheme, Fig. 6.1. In this case oil circulates by the
following path: oil tank – engine –cooler – oil tank. Fig.1 Direct scheme of
lubrication system
1 — engine;
2 — manometer;
3 — pressure pump;
4 — thermometer of oil
at engine inlet;
5 — suction pipeline;
6 — shut–off valve;
7 — venting; 8 — oil tank; 9
— scavenge pipeline;
10 — by–pass valve;
11 — cooler; 12 — filter;
13 — drain valve;
14 —thermometer of oil at
engine outlet;
15 — scavenge pump
Section of a lubrication system from oil pressure pump to scavenge pump
(including them) is an internal pipeline of the engine 1. Into an external
lubrication system enter: oil tank 8, cooler 11, suction (tank – engine) 5
and scavenge (engine – cooler – tank) 9, sections of pipelines, venting
pipeline 7, drain pipes and valves 13, instruments for measurement of
pressure 2 and temperature 4, 14 of oil and oil meter.
The suction pipeline should be direct, short and of big diameter. To improve
operating conditions of the pressure pump 3, it is possible to install the oil
tank above the pump.
The shut–off valve 6 is sometimes installed in the suction section, that
prevents from overflowing of oil through the switched off pump into the
inoperative engine. Thus it is necessary to block this valve with start–up of
engine.
For protection of lubrication system against a chip, a calx, a dust and a flux
from an oil tank, it would be expedient to install the filter in the pipeline
«tank – engine». But thus in a suction pipeline there will be a big
resistance. Thus altitude performance of lubrication system will go down.
Therefore filters 12 are installed in the scavenge section. The metal chip
on a surface of these filters is the first indicator of violation of a normal
operation of engine. Besides, filter grids are installed in the filler necks and
in the outlet connection of oil tanks.
To prevent storing oil and its emulsion in a casing of engine, volume flow of
scavenge pumps 15 should be in 2...3 times more, than pressure pumps
have. As the pumps except for the emulsion, pump out big quantity of air, it
results in additional saturation of oil by air.
The cooler 11 is equipped with the by–pass valve 10. This valve serves to
prevent breaking of cooler core at low temperatures of oil. This valve
promotes fast heating–up of oil. As at the open valve, oil circulates, omitting
the core. With heating of oil in lubrication system and decreasing of
pressure, the valve is closed and connects the cooler to activity.
The spring–loaded valves (Fig.2, а) are the simplest in design and reliable.
An essential disadvantage of these valves is, capability of passing of cold oil
through the cooler at low power of engine. Thus pumping is small and
resistance of cooler is small too. It increases heating–up time of oil, and in
flight (for example, at gliding) causes its super–cooling.
For this reason, the thermostatic valves (Fig.2, b) are preferable.
Such valves react to the oil temperature variation due to the silphon filled with
low–boiling liquid. With heating of oil, the silphon is extended, and the valve is
closed. Thus oil will flow only through core of cooler.
 Fig. 2. The schemes of by–pass valves
It is necessary to note, that purpose of venting of fuel tank and oil tank is different. In
fuel tanks, the air feed is required to provide specified overpressure in the fuel tank. In
oil tanks, discharge of air is required, as it comes in plenty from an engine together
with air–oil emulsion. Venting connections of oil tank are recommended to be directed
downwards, that oil could not accumulate and stiffen in them. It can cause breaking of
oil tank. For the same reason, venting is recommended to be directed in the warmed
place, for example, in a cooler tunnel behind an oil cooler.
Venting of lubrication system can be open and closed (through a breather system).
When designing the lubrication system, it is necessary to provide full, fast and reliable
drain of oil from the oil tank, cooler, filter sediment trap and pipelines. Convenient
access to drain valves should be provided.
It is necessary to prevent hitting of hot oil onto hands of ground maintenance
personnel, on electrical wiring, exhaust pipes, and wheel tyres.
Control over activity of lubrication system is carried out by pressure and temperature
of oil at engine inlet and by oil meter.
 Separation of air from oil

Passing through an engine, oil is saturated with air, gases and, in piston
engines, vapors of fuel. At lubrication of various units, bubbles of air are in
addition shattered. As a result, the air–oil emulsion is formed, this emulsion is
pumped out by scavenge pumps. Thus there is an additional saturation of oil
by air. Behind the cooler, pressure of oil drops, and additional air educes
from it. Thus oil, in which there are bubbles of various sizes, gets in the oil
tank. Size of these bubbles changes from molecular up to 10...20 mm in
diameter.
Large bubbles rapidly float and separate from oil. The less sizes of bubbles,
the less its speed of float, and it is more difficult to separate them from oil.
Floating time is directly proportional to viscosity and to height of oil column in
the oil tank. Thus with increase of time of presence of oil in the tank, quantity
of air passing to suction pipeline decreases. With increase of temperature of
oil, the floating time decreases, as viscosity decreases.
The following measures are taken for decreasing of contents of air in oil.
1. Reducing hydraulic resistances in pumpdown pipeline of oil.
2. Difference of pumping rates of scavenge and pressure pumps should be
chosen minimally required.
3. Installation of special de–aerators in the oil tank. They use a principle of
coagulation — enlargement of gas particles in two-phase medium.
4. Centrifugal de–aerators have the wide application now. They provide the
fullest separation of air from oil, and good altitude performance of a
lubrication system; however they demand power consumption.
Let’s note the disadvantages of direct scheme of lubrication system:
– Big back pressure, owing to presence of the cooler in a scavenge pipeline;
– Low temperature in the oil tank; hence oil viscosity is big and speed of
floating of air bubbles is low.
– Altitude performance of lubrication system of the direct scheme makes
7...8 km.
Owing to these disadvantages, other schemes of lubrication system are
widely used.
 The reverse scheme of lubrication system

Circulation of oil occurs according to the scheme (Fig.3): oil tank 11 – cooler
5 – engine 1 – oil tank.
Hot oil, not cooled in the cooler, gets directly in the oil tank. Viscosity of oil
considerably decreases. Speed of separation of air proportionally increases.
Besides, through absents of cooler, air bubbles are not shattered and remain
relatively big diameter; that also promotes fast air separation.
As the oil flowing through the cooler is cleared from air, heat rejection of
cooler increases. As oil from the cooler directly passes to the pressure pump,
the system faster reacts to regulating of cooling.
Pumping of oil through the cooler cannot be provided by the pressure pump.
Therefore reverse scheme of lubrication system demands the installation of
additional pump 9 in the segment «oil tank – cooler –engine». It is a
disadvantage of the reverse scheme.
Altitude performance of lubrication system of the reverse scheme makes
10...12 km.
 Fig. 3 Reverse scheme of lubrication system
1 — engine; 2 — manometer; 3 — pressure pump; 4 — thermometer of
oil at engine inlet; 5 — cooler; 6 — by–pass valve; 7 — suction pipeline;
8 — filter; 9 — transfer pump; 10 — venting; 11 — oil tank; 12 —
scavenge pipeline; 13 — scavenge pump
 The single–circuit scheme with a centrifugal de–aerator
Altitude performance of the direct scheme can be increased by the
installation of the centrifugal de–aerator 9 in pumpdown pipeline of oil, fig.4.

Fig.4. Scheme of lubrication system with a centrifugal de–aerator

1 — engine; 2 — pressure pump; 3 — suction pipeline; 4 — venting; 5 — oil tank; 6
— by–pass valve; 7 — scavenge pipeline; 8 — cooler; 9 — centrifugal de–aerator;
10 — scavenge pump
 Fig. 5. The centrifugal de–aerator
1 — casing; 2 — impeller; 3 — oil
exit pipeline connection;
А and В —
annular cavities

The centrifugal de–aerator (Fig. 5) is installed before the cooler. Thus

process of air separation is eased (as oil is hot). Besides heat rejection in
the cooler also increases, as oil is cleared from air.
This scheme is the most used on up–to–date turbojet airplanes.
 Shorted schemes
As the centrifugal de–aerator is capable to clear oil from air, there is no
necessity of circulation of oil through the oil tank. It has resulted in creation
shorted lubrication system (fig.6, 7).

Fig. 7. Shorted scheme of lubrication

Fig. 6. Shorted scheme of lubrication
system with the pump
system with the ejector
1 — engine; 2 — pressure pump;
1 — engine; 2 — pressure pump; 3 —
3 —suction pipeline; 4 — check valve;
suction pipeline; 4 — venting; 5 —
5 — transfer pump; 6 — venting; 7 — oil
ejector; 6 — oil tank; 7 — by–pass valve;
tank; 8 — by–pass valve; 9 — scavenge
8 — scavenge pipeline; 9 — cooler; 10 —
pipeline; 10 — cooler; 11 — centrifugal de–
centrifugal de–aerator; 11 — scavenge
aerator; 12 — scavenge pump
pump
Here oil circulates in the contour «the engine – the scavenge pump 11 – the
de–aerator 10 – the cooler 9 – the pressure pump 2 – the engine». The
ejector 5 serves only for compensation of the oil consumption.
Such scheme provides:
+ fast oil preheating (as preheated only the part of oil, which circulating in
the contour);
+ good altitude performance (due to a capability of creation a backup in the
main pump inlet, fig. 6.7);
+ small capacity (hence mass) of the oil tank. The store of oil consumed in
flight is kept in the oil tank only;
– As the tank is not used for cooling oil, the cooling surface of the cooler
(hence mass) should be more;
Such schemes of lubrication system are used on turboprop airplanes of
small and medium range (An-10, An-24).
 The double–circuit scheme of lubrication system
Double–circuit scheme of lubrication system (fig. 8) has the boost pump 5 and
two contours of flow of oil: the main and additional. The main contour includes:
the pressure pump 2 – the engine – the scavenge pump 13 – the centrifugal
de–aerator 12 – the cooler 11 – the pressure pump. Approximately 90% of oil
circulates in this contour. The residual 10% of oil pass in the oil tank for
preheating through the additional circuit (the cooler – the oil tank 7 – the boost
pump). Diameter of the bleed 8 in the additional circuit is selected by a condition
of passing of the optimal quantity of oil (approximately 10%) through it.
Advantages of the double–circuit scheme corresponds to advantages of the
shorted scheme. Such scheme is used in power plants of long range airplanes,
for example Il-62.
Fig. 8. Double–circuit scheme of
lubrication system
1 — engine; 2 — pressure pump;
3 — suction pipeline;
4 — check valve; 5 — transfer
pump; 6 — venting; 7 — oil tank;
8 — bleed; 9 — by–pass alve;
10 — scavenge pipeline; 11 —
cooler; 12 — centrifugal de–aerator;
13 — scavenge pump