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Piston Validation Criteria
Piston Validation Criteria
Piston Validation Criteria
Dep. 2
IT-C-V-15-002e October 2015
CONTENTS
1 INTRODUCTION ......................................................................................................................................... 3
2 OBJECTIVES ............................................................................................................................................... 3
TABLES
Table 1 Technical validation process ................................................................................................................ 4
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Table 6 Revisions during the duration test from technical validation to 10000 h ........................................... 16
FIGURES
Figure 1 Example of hot seizing test ................................................................................................................. 8
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1 INTRODUCTION
This document describes the tests to be made on the samples of pistons for their approval, for both existing
designs (due to a change of supplier) and for new designs.
This document gives the guidelines for validating the pistons, including performance tests on new pistons
and duration tests with oil consumption measurement.
2 OBJECTIVES
The objectives to be checked in the validation of rings are:
3 VALIDATION METHOD
The first step in the technical validation tests is the performance tests in the tests cell to discount any type of
problem that may arise. The objectives of the performance tests are:
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Main water
Load rpm Oil temp Oil level Duration Objective
temp
Piston profile, oil
PHAS Marking and oil
100% Nominal Nominal Nominal Nominal 100 h consumption and
E 1 consumption
blow-by
Minimum
Nominal/Max Nominal/ Minimu
100% Nominal 3.5 h installation
+ 10 ºC Max + 15º m
Hot seizing clearance
Piston and sleeve diameters that guarantee minimum clearance. The temperature must be
PHAS
increased in steps of 5 ºC for both oil and water, starting with nominal conditions and
E2
without exceeding the set limits. Each temperature state must last for 30 minutes.
Temperature in Piston operating
100% Nominal Nominal Nominal Nominal 2h
piston temperature
Sticking of rings
Overload 115% Nominal Max Max Nominal 100 h
and wear
Overspeed 100% 110% Nominal Nominal Nominal 200 h Hub resistance
PHAS Idle/ Resistance to
0/100% Nominal Nominal Nominal 200 h
E 3 Load cycles Nominal crown cracks
Load cycles variable from 0 to 100%
60/Max + 10 Resistance to
Heat cycles 0/100% Nominal Nominal Nominal 100 h
ºC seizing
Variable main water temperature cycles.
PHAS Wear
Duration 100% Nominal Nominal Nominal Nominal 2000* h
E4 Oil consumption
* The technical validation will end after 2000 h. However, the complete duration test must last for 10000 h, with
monitoring and intermediate and final inspections.
Diesel Gas
Nominal main water temperature 90 90/120
Maximum main water
temperature 96 96/126
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4 PERFORMANCE TESTS
o Rings:
Height.
Width.
Gap (free and when fitted in sleeve).
Roughness of friction face.
o Sleeve
Diameters: interior, exterior, flange.
Heights of sleeve, slots, flange.
Flatness of upper and lower flange faces.
Surface finish of interior diameter.
Coaxiality of the axes of the cylinders for fitting the sleeve in the block (upper
and lower gaskets areas) with respect to the piston’s internal sliding area.
Perpendicularity of the axes of the cylinders for fitting the sleeve in the block
with respect to the inner face of the flange.
- Installation
o Minimum piston-cylinder head clearance. Measurement of the free height of the piston to
the cylinder head using leads.
o Clearance of the rings in their grooves. They must be free and meet the clearances in
their manufacturing drawings.
o Height of sleeve tab with respect to the block: check that it is correct.
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Speed
Power
Fuel consumption
Oil consumption
Emissions: NO, NO2, CO, CO2, O2, THC, CH4
4.3 INSTALLATION
The pistons to be validated must be installed with new standard sleeves. The test must start with clean oil
and new oil filters.
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Tests of designs validated and now in production: Phases 1 and 2 in the validation table, Table 1.
Tests of new designs: Phases 1, 2 and 3 in the validation table, Table 1.
For monitoring the oil the following variables must be recorded daily (at the start and end of the daily test).
Engine
Date Oil hours Tank level
hours
day h h (litres)
Inspection: After the test, remove three pistons in in-line engines and six pistons in V engines for
inspection. If everything is correct (evaluated by the supplier either in place or by sending it
photographs/necessary measurements) the components analysed must be returned to their same
positions.
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Main water
Load rpm Oil temp Oil level Duration Objective
temp
Minimum
Nominal/Max Nominal/M Minimu
100% Nominal 3.5 h
installation
+ 10 ºC ax + 15º m
Hot seizing clearance
Piston and sleeve diameters that guarantee minimum clearance. The temperature must be
PHAS
increased in steps of 5 ºC for both oil and water, starting with nominal conditions and without
E2
exceeding the set limits. Each temperature state must last for 30 minutes.
Temperature in Piston operating
100% Nominal Nominal Nominal Nominal 2h
piston temperature
See the example test graph in Figure 1. The specific test graph must be prepared according to the nominal
and maximum temperatures for this specific engine.
Main ºC
Oil ºC
Limits
Temperature ºC
Time (min)
Inspection: After the test, remove three pistons in in-line engines and six pistons in V engines for inspection
(remove the same pistons as those after the tests in Phase 1 for see their development). If everything is
correct (evaluated by the supplier either in place or by sending it photographs/necessary measurements);
save these components. The components analysed must be returned to their same positions for the tests in
Phase 3.
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Install new pistons in the positions of those previously removed with templugs (specially-treated bolts
installed in the piece whose hardness depends on temperature) to obtain the piston’s map of maximum
operating temperatures. The pistons must have been fitted before hand by the manufacturer of the templugs.
The pistons must be fitted with the previously-removed rings, in the same positions.
The following example shows the suggested measurement points for a Ø 152 mm piston.
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Inspection: At the end of this test remove the instrumented pistons (three in in-line engines, six in V
engines) and send them for the maximum temperatures reached to be analysed.
For newly-designed pistons (Phase 3 necessary) re-install the components removed after the seizure test
in their same positions to start Phase 3.
If Phase 3 is not needed for the validation (existing design in production, new supplier), remove ALL the
pistons for final analysis after performance tests.
PHASE 3. OVERLOAD
Inspection: After the test, remove three pistons in in-line engines and six pistons in V engines for
inspection (remove the same pistons as those after the tests in Phases 1 and 2 to see the development).
If everything is correct (evaluated by the supplier either in place or by sending it photographs/necessary
measurements) the components analysed must be returned to their same positions for the next tests in
Phase 3.
PHASE 3. OVERSPEED
Inspection: After the test, remove three pistons in in-line engines and six pistons in V engines for
inspection (remove the same pistons as those after the tests in Phases 1 and 2 to see the development).
If everything is correct (evaluated by the supplier either in place or by sending it photographs/necessary
measurements) the components analysed must be returned to their same positions for the next tests in
Phase 3.
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Figure 3.
Load
Load [%]
Time [s]
Inspection: After the test, remove three pistons in in-line engines and six pistons in V engines for
inspection (remove the same pistons as those after the tests in Phases 1 and 2 to see the development).
If everything is correct (evaluated by the supplier either in place or by sending it photographs/necessary
measurements) the components analysed must be returned to their same positions for the next tests in
Phase 3.
See Figure 4 as an example of temperatures for engines, nominal 90 ºC, max 96 ºC. The specific
temperatures graph will depend on the engine.
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Main temperature ºC
Load [%]
Main ºC
Load
Time [min]
Inspection: After testing, remove ALL the pistons for final analysis by the supplier after performance
tests.
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5 DURATION TESTS
5.1 PRE-TEST MEASUREMENTS
The following measurements must be made.
- Components
o Pistons
Main diameters
Main heights
Roughness of skirt
Heights of ring grooves
Chamber volume
The manufacturer must provide reports on the measurements of the first
samples with at least:
Main dimensional measurements
Inclination, straightness and undulation of the upper and lower surfaces
of the grooves
Perpendicularity of the grooves’ working surface with respect to the axis
of the piece
Lower half angle of the compression ring groove and its total angle.
Piston crown profile from the top to the end of the skirt
Roundness of the skirt
o Rings
Height
Width
Clearance (free and when fitted in sleeve)
Roughness of friction face
o Sleeve
Diameters: Interior, exterior, flange
Heights of sleeve, slots, flange.
Flatness of upper and lower flange faces.
Surface finish of interior diameter.
Coaxiality of the axes of the cylinders for fitting the sleeve in the block (upper
and lower gaskets areas) with respect to the piston’s internal sliding area.
Perpendicularity of the axes of the cylinders for fitting the sleeve in the block
with respect to the inner face of the flange
Oil consumption.
Sump oil temperature.
Sump pressure.
Temperature in engine’s main circuit.
Inlet manifold temperature.
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5.3 ASSEMBLY
It is recommended that the pistons duration tests be made in V engines because of the larger number of
units available for analysis afterwards.
The new rings must be installed with new sleeves and pistons.
X . YY
EngineNnumber
º motor N ºcilindro
Cylinder number
These pistons must be marked on the orientation hub at the bottom of the piston.
The pistons to be tested must be installed with new standard sleeves. The pistons se must be marked on
the bottom edge with:
X . YY
EngineNnumber
º motor N ºcilindro
Cylinder number
The test must start with clean oil and new oil filters.
The following information must be recorded for sending to Guascor R&D for each engine:
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5.4 TEST
5.4.1 DURATION
The minimum duration of the validation tests must be 2000 hours. If after 2000 h the pistons analysed are
OK, the technical validation is considered concluded. However, the duration test must continue with
suitable monitoring to complete 10000 hours.
5.4.2 RECORDS
The information recorded in the engine during the pistons tests (power, pressures and temperatures), and
the log of work to the engine (scheduled and unscheduled due to faults) and of alarms must also be sent
to Guascor R&D.
The monitoring of the oil consumption is primordial in this test, so it must be recorded every 50 hours
and sent periodically to Guascor R&D (every two weeks). The power generated by the engine must also
be noted (MWh). The temperatures of the oil, main water and inlet manifold must also be taken every 50
hours. The sump gases pressure must also be noted every 150 h.
The table with the data to be filled in for monitoring the oil consumption, the oil temperature and the sump
gases pressure is shown below.
The engine must have an alarm system to stop it because of high sump gases pressure.
5.4.3 INSPECTIONS
For in-line engine: Remove one piston with its rings for inspection. Send the piston
to the supplier for analysis. Replace with new piston.
For in-line engine remove piston 1
1000 h
For V engine: Remove two pistons with their rings for inspection. Send the pistons to
the supplier for analysis. Replace with new pistons.
For V12 engine remove pistons 1 and 10.
For V16 engine remove pistons 1 and 12.
Remove two pistons with their rings for inspection in both in-line and V engines.
Send the pistons to the supplier for analysis. Replace with new pistons.
2000 h For in-line engine remove pistons 2 and 5
For V12 engine remove pistons 3 and 7
For V16 engine remove pistons 3 and 14
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Remove one piston with its rings for inspection (in both in-line and V engines). Send
the piston to the supplier for analysis. Replace with new piston.
4000 h
For in-line engine remove piston 3
For V engine remove piston 6
Remove one piston with its rings for inspection (in both in-line and V engines). Send
the piston to the supplier for analysis. Replace with new piston.
8000 h
For in-line engine remove piston 6
For V engine remove piston 11
Remove one (6L)/two pistons with their rings for inspection. Send the pistons to the
supplier for analysis. Replace with new pistons.
For in-line engine 6L remove piston 4 (the only remaining one with 10000 h)
10000 h
For in-line engine 8L remove pistons 4 and 8.
For V12 engine remove pistons 4 and 8.
For V16 engine remove pistons 7 and 9.
Vernolab_templug.pd
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TEMPLUGMAN.pdf
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