ΔΙΚΤΥΑ ΛΑΔΙΟΥ ΚΑΙ

ΒΟΗΘΗΤΙΚΑ
ΜΗΧΑΝΗΜΑΤΑ
Δρ. Γεώργιος Α. Λιβανός
Content of the course

 Lubricating oils and their properties

 Lubricating oil systems / Internal
 Lubricating oil systems / External
 Crankcase ventilation
 Product information
• LO separator
• Filters
• Coolers
• Pumps
• Thermostatic valves
Lubrication oil: Mission
A well working lube oil system is vital for a trouble free operation of an egnine. It’s a matter
of seconds if the oil pressure is lost before the troubles begin.

Mission for Lube oil

1. To lubricate moving parts in the engine to minimise friction.
2. To act as a cooling system for bearings etc.
3. To transport harmful particles away from bearings etc.
4. To neutralise corrosive combustion acids to prevent corrosion.

Lube oils in Wärtsila

• Only lube oils approved by Wärtsilä allowed.
• Main lube oil characteristics:
• SAE 40 viscosity grade
• BN* for Gas engines 4-7 mg KOH/g
• BN for Liquid fuel engines 10 - 65 mg KOH/g**

* BN means Base number

** Depending on Sulphur content in fuel
Typical composition of a trunk-piston diesel engine oil

Additives Improvement on

Detergents Engine cleanliness

15-25%
Overbased system (BN) Cold corrosion
Additive Dispersants Engine cleanliness
EP/AW agents Engine wear
Oxidation inhibitors Oil oxidation
Antifoamants Oil foaming

Additive carrier
75-85%
Base oils Blending principles
Base oils
Neutrals Base oils with different
viscosities are used
Bright stock to obtain the right
viscosity grade
 Important properties
PROPERTY CHANGE IN IMPACT ON CONDEMNING LIMIT
PROPERTY ENGINE OPERATION (HFO OPERATION)

Base number Low base number Corrosive wear min. 20 mg KOH/g

Liner, piston ring groove
Insolubles High insolubles Dirty engine max. 2.0 % m/m
content Deposit formation in n-pentane
Wear of bearings etc.
Viscosity High viscosity More friction 45% increase at 40 °C
Reduced cooling 25% increase at 100 °C

Low viscosity Thinner oil film 25% decrease at 40 °C

Metal - metal contact 20% decrease at 100 °C

Water content High water content Deterioration of oil film max. 0.3 % V/V
Bearing damage
Fresh lubricating oil requirements for 4-s diesel engines

 SAE 40 viscosity grade

 Viscosity index (VI) of the finished lubricant min. 95
 Use of VI improvers not allowed
 Base number depending on SLOC and fuel quality:
 LFO: 10 – 20 (30) mg KOH/g
 LBF: 10 – 20 mg KOH/g
 HFO: (30) 40 - 65 mg KOH/g
 Foaming characteristics, acc. to ASTM D892, max.
 Sequence I: 100/0 ml
 Sequence II: 100/0 ml
 Sequence III: 100/0 ml
 Virgin base stocks to be used (recycled or re-refined base oils
not allowed)
 Additionally, attention is paid to additive technology
Fresh lubricating oil requirements for 4-s gas engines

 Viscosity grade: SAE 40

 Viscosity index (VI) of the finished lubricant min. 95
 Use of VI improvers not allowed
 Base number on continuous natural gas operation: 4 -7 mg KOH/g
 Sulphated ash content: max. 0.6 % m/m
 Foaming characteristics, acc. to ASTM D892, max.
 Sequence I: 100/0 ml
 Sequence II: 100/0 ml
 Sequence III: 100/0 ml
 Virgin base stocks to be used (recycled or re-refined base oils
not allowed)
 Bright stock amount: max. 10 % m/m
 Properties

Viscosity:  Measure of fluid’s

resistance to flow
 Viscosity increase
indicates:
170
 oil oxidation
 presence of soot &
160
combustion
originated material
150
 HFO leakage to
lube oil
140
 Viscosity decrease
indicates LFO leakage
130
to lube oil
 Wärtsilä’s limit:
120
0 1000 2000 3000 4000 5000
 -20% / +25%
OIL SERVICE HOURS (h) change @ 100 °C
VISCOSITY AT 40 °C VISCOSITY AT 100 °C
 -25% / +45%
change @ 40 °C
 Properties
 Describes the available
Base Number (BN):
alkali reserve in lube oil
 BN is decreasing when
55
acid sulphur and
50 nitrogen originated
combustion residues
45
are reacting with alkali
40 reserve
 SLOC and fuel S content
35
are the main factors
30 influencing on BN
depletion rate
25
 Limit:
20
 min. 20 mg KOH/g
0 1000 2000 3000 4000 5000 on HFO operation
OIL SERVICE HOURS (h)
 max. 50%
depletion on LFO
operation
Reasons for oil change, HFO operation

100

80 75 75

60

40

20 20
20

5 5

0
Viscosity Insolubles
1 Other Base Number Viscosity
2 Other

Without anti-polishing ring With anti-polishing ring

Reasons for oil change, HFO operation

 Though all analyzed used lubricating oil properties are indicating that
lubricating oil is suitable for further use, it may be that oil has partly
lost its capability to keep engine component surfaces clean

 This leads to too thick deposit layers, like:

 Piston cooling gallery -> hot corrosion of piston top
 Piston ring groove area -> scuffing
 Cold engine components -> cosmetic issue, but still not acceptable

 Thus the following lubricating oil properties are considered very

important in order to achieve long lubricating oil change intervals
 Thermal stability
 Oxidation stability
 Compatibility with fuel originated compounds
 Correct choice of BN
Continuous heavy fuel operation:

 BN condemning limit of used lubricating oil: min. 20 mg KOH/g

 In the first place the use of BN 50+ lubricants is recommended,
especially if fuel sulphur content is above 2.0 % m/m
 BN 40 lubricants can be used as well, if experience shows that BN
equilibrium will remain acceptable
 BN 30 lubricants are recommended to be used only in exceptional
cases (SCR catalyst, very low sulphur residual fuel)
 Benefits to use higher BN lubricating oils:
 longer lubricating oil lifetime
 better cleanliness of engine components
 lower wear of piston ring grooves
 Correct choice of BN
Continuous distillate fuel operation:

 BN condemning limit of used lubricating oil: max. 50% depletion

compared to fresh lubricating oil BN
 BN 10 - 20 lubricants are typically used
 BN 30 lubricants can also be used but are not needed
 Even with very low sulphur fuels BN 10 (fresh oil) is the minimum requirement
 Neutralisation of the oxides of nitrogen is also important
Periodical distillate / residual fuel operation:

 Minimum BN 30 lubricating oil is requested, since lubricating oil must be

chosen according to “worse” fuel quality
 Correct BN choice (30, 40, 50+) depends on how much is operated with
distillate / residual fuel and what is the sulphur content of those fuels
 BN condemning limit of used lubricating oil: 20 mg KOH/g
Types of lubrication
Load
Load

Movement

Bearing Oil out Oil out

Oil in
Hydrodynamic lubrication Hydrostatic lubrication

Boundary lubrication Metal to metal contact

 Example of wear rates

 Corrosive wear increases at

higher fuel sulphur levels
Wear, mm/10000 h

 Corrosive wear decreases

High sulphur fuel dramatically at higher BN

Low sulphur fuel

0 5 10 15 20 25 30
BN, mg KOH/g
 Oil film thickness
Function of Oil film thickness
 Viscosity  Speed Pressure
 Temperature  Pressure (Load)
Speed
 Viscosity index

Oil film thickness

Viscosity index
Viscosity

Low VI
High VI

40 100 Viscosity * Speed

Temperature, °C Pressure
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
Cooling of engine components
 Bearings
 Pistons

Example of average oil temperature in piston

120

110
TEMPERATURE (°C)

OIL TEMP ERATURE OUT OF P ISTON

100

90

80

OIL TEMP ERATURE INTO P ISTON

70
0 25 50 75 100 125
ENGINE LOAD (% )
Cylinder liner corrosion
Corrosive wear of cylinder liner due to operation
with too low BN level of used lubricating oil
Piston cooling gallery cleanliness

Influence of piston cooling gallery deposit thickness

on piston top temperature
250

Limits:
200 Bigger Engines
- aver. 300 mm
150
- max. 400 mm
Smaller Engines
- aver. 200 mm
100
- max. 300 mm

50

0
0 200 400 600 800 1000

DEPOSIT THICKNESS [m]

Piston cooling gallery cleanliness

Piston cooling gallery

Deposit thickness
300 - 600 m
 Fuel leakage
Heavy fuel leakage to lubricating oil causes
 Increase of lubricating oil viscosity
 Increase of bearing temperature

270
LUBRICATING OIL VISCOSITY [cSt @ 40 °C]

240

210

180

150

120
94 96 98 100 102 104 106
BIG END BEARING TEMPERATURE [°C]
 Fuel leakage
Oil properties indicating the presence of fuel in lubricating oil
 Decreased flash point (PMCC method better than COC method)
 Increased viscosity on HFO operation
 Decreased viscosity on LFO operation
 Increase rate of insolubles higher than expected
 BN depletion rate faster than expected
 Difference in the contents n-pentane and n-toluene insolubles
 Abnormally high vanadium & nickel contents on HFO operation

 Detection of fuel from LFO operated engine is easier than

from HFO operated engine
Foaming
Reasons to foaming of lubricating oil
 Leakage in turbocharger
 Leakage in lube oil pump
 Abnormally high blow-by
 Poor design of lube oil system
 Lube oil quality problem
 Presence of contaminants in lube
oil system (grease, rust
preventives, silica gel bags)
Internal Lube Oil systems: wet sump
Internal systems: dry sump
27 © Wärtsilä 01/05/2024
Presentation name / Author
External systems: Genset

28 © Wärtsilä LO SYSTEM
TRAINING MATERIAL
Presentation name / Author,
DocumentID:
External systems: main engine
External systems: NO engine driven LO pump
External systems: System oil tank
Product info: Separators

 Removal of particles and water with centrifugal separators

 Separators are dimensioned for continuous separation.
 One separator/engine to avoid mixing up bad lube oil in several engines.
 Usually located close to engine (In free end on engine on top of EAM or FOM).
 Separating temperature 95°C. El or steam heater included in separator module.
 Capacity depending on engine output and fuel quality.
 Separator usage depending on the type of fuel used:

HFO Applications: Yes

LFO Applications: No, (yes if low quality LFO ISO-F-DMC is used)
DF tri-fuel Applications: Yes

DF Applications: No
SG Applications: No
Product info: Separators

Lube oil Separator module

main components

• Separator
• Feed pump
• Heater (steam or el)
• Steam control valve
• Control system and el cabinet
• Water block
• Sludge tank
• Sludge pump
• Air connections
• Pipes and connections
Product info: Separators

Dirty oil in
Clean oil out
Separator working principle
Water out

Sludge out
to sludge tank
Components

 1N02, 1N05 Separator

unit
 www.alfalaval.com
Components - filters

 1F3, 1F05, 1F07 duplex

filter
 Boll & Kirch
 Filter elements can be
cleaned
 Disposable elements
available
 Max flow and fineness
 www.bollfilter.de
Product info: Automatic filters
Automatic back flushing filter
 Mesh size 30 μm.
 Self cleaning with back flushing oil.
 Automatic filter used on most power
plant engines (except WV32 based
engines).
 Can be built on the engine or separately
in the pipe module.
Product info: Automatic filters

 Automatic back flushing

 filter function

 1 Dirty oil Inlet

 2 Clean oil outlet
 3 Back flushing oil outlet (4-8%
of total flow)
 4 Turbine
 5 Filter candles
 6 Overflow valve (Sp 2 bar)
 7 Safety filter
 8 Differential pressure indicator
Product info: Automatic filters

lube oil automatic automatic lube oil filter on engine

filter off engine
Product info: Coolers

 Lubricating oil has to be cooled from normal operating temperature at full load (75-
80°C) to nominal inlet temperature (60-68°C, depending on engine type).
 The cooling media is normally taken from the low temperature circuit (LT water).
 Cooler can be built on engine or separate.
 A 3-way thermostatic valve is handling the control of the LO temperature, mixing cold
oil from the cooler and warm oil from the engine.
 Product info: Coolers

W32/34SG Lube Oil cooler on engine

50DF/46 Lube oil cooler off engine

Components

 1E04 tube and shell cooler

 Tolerates pulsation
 Lower O.H.T.C. compared
to PHE
 www.hs-cooler.de
Components

 1E04 plate heat exchanger

 Easy to service
 Capacity can be increased
 www.alfalaval.com
Components

 1E04 data sheet

 Heat capacity
 Temperatures
 Flows
 Pressures
 Extra surface
 Materials
Product info: Pumps

 The pressure control system has to provide the lubricating oil

system with the flow of lubricating oil at the right pressure.
This includes following components:

 Main lubricating oil pump

 Engine driven.
 Internal pressure control valve.
 Nominal Pressure 4.5 bar.

 Pre lubricating oil pump

 Nominal Pressure 0.5…1.5 bar depending on engine type.
 Pressurizing the system before start-up.
 Providing additional capacity to the engine driven lubricating oil pump if
needed (e.g. running on low rpm).
 outside the engine for 46/50DF and 20V32. All other have it on-built
Product info: Pumps
Engine on-built main lube oil pump and pre-lube
pump

Main lube oil pump

Pre-lube oil pump