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MANISH

LUB OIL SYSTEM


CPL, BAWAL
Manish Vijay

1 © Wärtsilä 10 April 2018 Lube oil System


LUBRICATING OIL SYSTEM

• Just like health of human body depends on blood circulation, Health of


engine depends on circulation of lube oil in all parts of Engine:

 It Lubricates

1) Piston

2) Cylinder liner

3) All bearings

4) Gears

5) Cooling water & Lube oil pumps

6) Fuel injection pumps (Not in our case)

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2 © Wärtsilä 10 April 2018 Presentation name / Author


LUBRICATING OIL SYSTEM

OUR LUBRICATION OIL SYSTEM IS FORCE FEED


LUBRICATION SYSTEM.

THE FORCE FEED LUBRICATING OIL SYSTEM


LUBRICATES ALL RUNNING PART’S TO MINIMISE
FRICTION LOSSES.

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What is Health OIL
LUBRICATING andSYSTEM
Safety?
1.LUB OIL SUMP
2.LUB OIL PUMP / PRE LUB OIL PUMP
3.LUB OIL COOLER
4.LUB OIL FILTER
5.LUB OIL MAIN GALLERY
6.CAMSHAFT BEARINGS
7.ROCKER ARM
8.PUSH ROD
9.VALVE TAPPET
10.TURBO CHARGER
11.MAIN BEARING
12.CRANK SHAFT
13.CONNECTING ROD BIG END BEARING
14.CONNECTING ROD SMALL END BEARING
15.PISTON PIN
16.PISTON
17.LINER
18.SUMP
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By Law an Employer
LUBRICATING OIL SYSTEM
has to;

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Why OHSMS OIL SYSTEM
LUBRICATING
1. Centrifugal filter
2. Lubricating oil cooler
3. Lubricating oil automatic filter
4. Thermostatic valve
5. Intermediate gear wheel bearings
6. Rocker arms
7. Push rods
8. Valve tappets
9. Camshaft bearings
10. Crankshaft
11. Oil dipstick
12. Gudgeon pins
13. Piston
14. Lubricating oil to turbocharger
15. Nonreturn valve
16. Lubricating oil pump
17. Prelubricating oil pump

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LUBRICATING OIL SYSTEM

• Functions of lube oil


• Cools

Piston crown

All bearings

Gears
• Cleans

Carbon deposits

Dirt

Sulphated deposits
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LUBRICATING OIL SYSTEM

• Functions of lube oil :

• To prevent corrosion

Cold corrosion in liner, valve guide

• Seal

Fuel ingress in fuel injection pump

Blow-by from combustion area


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8 © Wärtsilä 10 April 2018 Presentation name / Author


LUBRICATING OIL SYSTEM

Pre lube pump


The electrically driven lubricating pump is a Gear type pump equipped with an
overflow valve. The pump is used for:
• Filling of the engine lubricating oil system before starting
• Continuous prelubrication of stopped engine

Pressure controller valve


It is very important to keep the correct pressure in order to provide efficient
lubrication of bearing and cooling of piston
• The pressure in distributing pipe line is regulated by a pressure control valve.
• The pressure can be adjusted by means of a Set Screw on control valve
Note :
• Transducer is used for measurement of priming pressure , Alarm & Shut-down for
low lube oil pressure.
• The pressure can rise above the normal value when starting with cold oil but will
return to the normal when the oil is heated

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LUBRICATING OIL SYSTEM

•Lube Oil Quality

•Additives

•Base Oil
•Lube Oil

•Lubricating oil composition


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10 © Wärtsilä 10 April 2018 Presentation name / Author


LUBRICATING OIL SYSTEM

•Lubricating oil composition


•Additives •Improvements on
• Detergents • Engine cleanliness

• BN • Cold corrosion
•15 - 20 % • Dispersants • Engine cleanliness

• EP / AW agents • Engine wear

• Oxidation Inhibitors • Oil oxidation

• Antifoamants • Oil foaming


•Additive Carrier •Blending Principles
•85 - 80 % • Base Oils
• Neutrals • Base oils with different
viscosities are used to
• Bright stock
obtain the reight viscosity
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grade

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LUBRICATING OIL SYSTEM

•Lube Oil •Lube Oil Quality


•Lubricating /
Cooling
•Deposits
•Fe Cr Sn S
•Carbon
•S V

•Na H 2O

•Ni Al

•C Si •Heat
•Cr Asp. •Oxidation •Separator

•C Fe •Carbon •Sludge, H2O

•Fuel
MANISH / •Fe, Na, Al, •Back to
Combustion Cu, Si, C, Cr work
12
process
© Wärtsilä 10 April 2018 Presentation name / Author
Employees Obligation
LUBRICATING OIL SYSTEM
Important characteristics of lub oil
1 viscosity :- Viscosity is defined as a measurement of resistance to
flow and is a KEY physical property of lubricants. Industrial lubricating
oils are generally measured at 40° C and results are reported as
centiStokes (cSt). Engine Oils are most often measured at 100°
C. Most industrial lubricating oils are classified by their viscosity. For
example, an ISO Viscosity Grade 32 (ISO VG) will have a viscosity of
32 cSt @ 40° C, ± 10%. Engine oils are classified by their Society of
Automotive Engineers (SAE) grade. SAE 20 or SAE 30 for
example. Engine oils often have additives that give them multi-grade
characteristics, such as SAE 10W40. This refers to the oil that has the
viscosity characteristics of an SAE 10 oil when it is cold, and the
viscosity characteristics of a SAE 40 weight oil in normal
temperatures. Viscosity of oils is inversely proportional to temperature.
12.5 – 16.0 cst @ 100°C

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13 © Wärtsilä 10 April 2018 Presentation name / Author


Why OHSMS OIL SYSTEM
LUBRICATING

Drop viscosity :Viscosity decreases are almost always a


result of contamination, either with fuel in the case of
engine oils, or product in the case of industrial oils.
Rise viscosity : Viscosity increasing is normally a result of
lubricant oxidation and degradation or contamination with a
higher grade oil.
Oxidation Presence of insolubles
Neutralisation : As lubricants degrade from oxidation they
form a number of acids. These acids are corrosive to
yellow metals, carbon steel, cast iron, and if left
uncorrected for a period of time will begin a corrosion
process and possibly eventual bearing failure

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LUBRICATING OIL SYSTEM
Benefits

Flash point : The Flash Point of an industrial lubricant is an


important test to determine if light-end hydrocarbons are
getting into the oil through seal leaks or other means. It is
an effective way to monitor seal performance in light end
hydro-carbon compressors. Low Flash Points pose a safety
hazard in the event of component failure than can generate
heat above the flash point of the oil, such as bearing
failure. Generally, the more viscous and the more additives
in the oil, the higher the Flash Point. A typical automotive
or diesel engine oil will have a Flash Point in the 250°C
Alarm level :- 190°C(50°C less from fresh oil)
Rejection limit :- 150°C

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15 © Wärtsilä 10 April 2018 Presentation name / Author


How an OHSMS
LUBRICATING OIL
should
SYSTEM
be ?

TBN :- Total base number


High Sulphur content
Bad adjustment of H.T. Water
Precipitation of additives due to water presence

WATER CONTENT :-
Normal 0.1%
Alarm Limit 0.3%
Rejection Limit 0.5%

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16 © Wärtsilä 10 April 2018 Presentation name / Author


LUBRICATING OIL SYSTEM

•Base No. - BN or TBN

• Calcium Carbonate - CaCO3 - Alkaline

• Expressed as mg KOH/g of oil

• Carried by detergents

• Neutralizes acid products

• H2SO4 + CaCO3 = CaSO4 + H2O + CO2

• BN also gets depleted

• Sulphated ash deposits

• Sulphate & water removed in centrifuge


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LUBRICATING OIL SYSTEM

Depletion of BN - Possible Solutions


Addition of BN chemicals into oil
• Mixing problem - precipitation
• Artificial consumption
• Step backwards - costly
• Low sulphur fuel
• Non-availability - costly
• High initial TBN oil
• Best solution

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Governing Principles
LUBRICATING OIL SYSTEM

DETERGENCY :-Detergents neutralize strong acids present


in the lubricant (for example sulfuric and nitric acid
produced in internal combustion engines as a result of
combustion process) and remove the neutralization
products from the metal surface. Detergents also form a
film on the part surface preventing high temperature
deposition of sludge and varnish.
Detergents are commonly added to Engine oil.

Phenolates, sulphonates and phosphonates of alkaline and


alkaline-earth elements, such as calcium (Ca), magnesium
(Mg), sodium (Na) or Ba (barium), are used as detergents
in oil

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LUBRICATING OIL SYSTEM

DISPERSANCY :-Dispersants keep the foreign particles


present in a lubricant in a dispersed form (finely divided and
uniformly dispersed throughout the oil).
The foreign particles are sludge and varnish, dirt, products
of oxidation, water etc.

Long chain hydrocarbons succinimides, such as


polyisobutylene succinimides are used as dispersants in
lubricants.

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20 © Wärtsilä 10 April 2018 Presentation name / Author


LUBRICATING OIL SYSTEM

 ANTI-WEAR :- Anti-wear additives prevent direct metal-to-


metal contact between the machine parts when the oil film
is broken down.
Use of anti-wear additives results in longer machine life due
to higher wear and score resistance of the components.
The mechanism of anti-wear additives: the additive reacts
with the metal on the part surface and forms a film, which
may slide over the friction surface.

The following materials are used as anti-wear additives:


 Zinc dithiophosphate (ZDP);
 Zinc dialkyldithiophosphate (ZDDP);
 Tricresylphosphate (TCP).
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LUBRICATING OIL SYSTEM

• EXTREME PRESSURE :- Extreme pressure (EP) additives


prevent seizure conditions caused by direct metal-to-metal
contact between the parts under high loads.
The mechanism of EP additives is similar to that of anti-
wear additive: the additive substance form a coating on the
part surface. This coating protects the part surface from a
direct contact with other part, decreasing wear and scoring.
The following materials are used as extra pressure (EP)
additives:
Chlorinated paraffins;
• Sulphurized fats;
• Esters;
• Zinc dialkyldithiophosphate (ZDDP);
• Molybdenum disulfide
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LUBRICATING OIL SYSTEM
ANTI FOAMING :- Agitation and aeration of a lubricating oil
occurring at certain applications (Engine oils,Gear
oils, Compressor oils) may result in formation of air bubbles
in the oil - foaming. Foaming not only enhances oil
oxidation but also decreases lubrication effect causing oil
starvation.

Dimethylsilicones (dimethylsiloxanes) is commonly used as


anti-foaming agent in lubricants

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LUBRICATING OIL SYSTEM

•Lube Oil Quality


Lube oil quality - Deterioration

Three main causes

• Oxidation

• Contamination

• Additives depletion

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LUBRICATING OIL SYSTEM

Oxidation

• due to very high temperature

• increased viscosity

• thermal cracking

• deposits in hot zone

• weak acids - bearing corrosion

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LUBRICATING OIL SYSTEM

Contamination
• Soot

• blow-by

• sludge in cold zone

• Fuel

• decreased flash point

• Water

• leakage, condensation,
separator malfunctioning
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LUBRICATING OIL SYSTEM

Additive depletion

• Sulphurous gases from


combustion

• neutralization process

• depletion of TBN

• Precipitation

• Foaming

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27 © Wärtsilä 10 April 2018 Presentation name / Author


LUBRICATING OIL SYSTEM

Lube oil Analysis

• To know condition of engine components

• wear of bearings, piston rings, gears

• to prevent cold corrosion

• to ensure safety of engine

• To determine period for changing oil

• optimum life - economy


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LUBRICATING OIL SYSTEM

Lube oil Analysis

• Regularly - every 500 hours

• Correct sampling - true representative of lot

• From flowing oil (e.g. inlet to engine)

• Always from same sampling point

• Never from sump or drain point

• 1 liter sample

• Details - eng. run. hrs, oil run. hrs, oil type, sampling point,
type of fuel, make-up quantity
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LUBRICATING OIL SYSTEM

Lube oil Analysis


Results Interpretation

• Absolute values - limits

• e.g. max. viscosity, min. flash point

• Trend analysis

• e.g. wear metal particles

• Sudden change in trend is an indication of


abnormality

• Actions before breakdown


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LUBRICATING OIL SYSTEM

Elemental analysis
Elements are here divide in to three groups according to their origin.
1. Wear metals
The most common wear metals in lubricating oil analyses are
• Iron ( Fe) :- reflects mainly piston and cylinder liner were
Fresh oil may contain a small amount(<15 ppm) of iron originating from
transfer pipe line or tanks.
If the oil is not delivered as a bulk Note that iron may also be used as an
additive in some lubricating oil formulation.
• Chromium (Cr) :- Indicates mainly piston ring wear

• Lead (Pb) :- present in overlays of gudgeon pin, bearing bushings,


camshaft bearings, bearing bushing for camshaft end and thrust washer

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LUBRICATING OIL SYSTEM

Copper (cu) :- Copper can enter in lubricating oil from


• Lubricating oil Pump bearings
• Bronze bearing of rocker arms
• Roller pins for tappets and gudgeon pin bearing bushing
If cu content is abnormally high( >10 – 15 ppm) one possible reason is
presence of exhaust gases in the inlet air
Tin (Sn) : -possible sources for tin are big end bearings, main bearings,
gudgeon pin bearing & Bushing, camshaft bearing, bearing bushing of
camshaft end and thrust washer.

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LUBRICATING OIL SYSTEM

In the engine components there can be smaller amounts of


• Aluminum (Al)
• Molybdenum (Mo)
• Nickel (Ni)
• Antimony ( Sb)
Aluminum & Nickel may enter the lubricating oil from engine parts.

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LUBRICATING OIL SYSTEM

2. External source elements


• Presence of sodium can indicate sea water leakage through central
cooler or water leakage in the closed cooling water system.
• The most commonly used cooling water additives are sodium nitrite
+sodium borate and sodium molybdate based products

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34 © Wärtsilä 10 April 2018 Presentation name / Author


LUBRICATING OIL SYSTEM

3. LUBRICATING OIL ADDITIVES


Calcium (Ca), phosphorus (P), Zinc (Zn) are normally used in lubricating oil
additives packages.
• Calcium :- content is depending on the BN, the higher the BN the Higher the Ca
content.
• Phosphorus & Zinc contents are depending on the additive chemistry used in
each specific case and can very significantly
In most low ash lubricating oils used by wartsila medium-speed Gas engine
• The P content of the fresh oil is around 200 – 300 ppm
• The Zn content around 200 – 300 ppm
In used lubricating oils these values can be somewhat lower.
• Silicon (Si) : - is typically used as an antifoaming component in lubricating oils.

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LUBRICATING OIL SYSTEM

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LUBRICATING OIL SYSTEM

Lube Oil Contamination & Limits


Interpretation of analysis reports by trend monitoring
Normal Alarming
value value
• Viscosity SAE 40 100oC cSt 11-19
• 40oC cSt 110-212
• Viscosity SAE 30 100oC cSt 9-15
• 40oC cSt 70-140
• Flashpoint PMCC 40oC oC >200 170 min.
• TBN mgKOH/g 20 min.
• n-Pentane insolubles% m/m 1.5 max
• Toluene insolubles % m/m 1.5 max
• Water % v/v 0.05 (new) 0.3 max

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LUBRICATING OIL SYSTEM
• Lube Oil Contamination & Limits
• Average value Alarming value
Iron Fe ppm 17 40
• Chromium Cr ppm 1.5 5
• Molybdenum Mo ppm 1.3 10
• Tin Sn ppm 2.0 10
• Lead Pb ppm 2.1 9
• Copper Cu ppm 3.2 10
• Nickle Ni ppm 26 80
• Sodium Na ppm 37 90
• Vanadium V ppm 82 250
• Magnesium Mg ppm 33 75
• Aluminium Al ppm 5.3 20
• Ca, P, Zn & Si Vary too much as per oil type & mfr.
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LUBRICATING OIL SYSTEM

•Questions ??

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39 © Wärtsilä 10 April 2018 Presentation name / Author

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