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Lloyds Register: Marine

DANNY SHORTEN IENG


45, Husband, Father, Bass Guitarist, Cook Craft Apprenticed, Mechanical Engineer, BTEC HND 1985. 1981 1999 Lubricants Company - Field support testing and engineering industrial lubricants, condition monitoring and service products. 1999 2010 Lloyds Register of Shipping Marine and offshore systems oil analysis, Condition Based Maintenance, Condition Monitoring large marine engines.

Lloyds Register: Marine

Lloyds Register Condition Monitoring Guide Published 2010 Marine Machinery Condition Monitoring A training standard for practitioners http://www.bindt.org/COMADIT/CM_Certification.html
Meets ISO 18436 and MNTB requirements

ISO TC108 SC5 Condition Monitoring UK Representative Marine

CIMAC Large Engine Lubrication Group Member CEC - Large engine lubricant test methods development Currently responsible for FOBAS Engine delivery and technical support re: CBM for classification group.

Lloyds Register: Marine

A new approach to engine performance analysis 1.Diagnoses based upon cylinder drain oil analysis pros and cons 2.What can integrated fluid analysis techniques actually tell us? 3.What can the ship manager, superintendent and chief engineer expect to gain from this approach? 4.The importance of creating a functional enterprise between internal operations and external consultancy support

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Consultancy services

http://www.lr.org/sectors/marine/Services/Consultancy/FOBAS/

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FOBAS Engine

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Slow Speed 2st Engines

Two lubrication Systems

1 - Cylinder Oil 2 - System or Crankcase

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FOBAS ENGINE
Optimisation of 2 stroke engine performance
Sources of piston ring / liner wear

Targeting minor combustion issues is the most effective way to improve engine reliability

Data Source

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CLO Feed

Cylinder Drain Oil contains useful information about:


Combustion Quality
Sampling Point

Wear Condition Adequacy of Feed Condition of Stuffing Box Water Contamination

CLO Drain

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FOBAS Engine

Scrape Down Oil

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FOBAS Engine

Scrape Down Oil

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Increased sensitivity to emerging conditions


PF Curve Machine condition
P = Point where failure indicator can be measured F = Point where failure occurs

FOBAS Engine P

Scrape down analysis and


Less machinery deterioration

other forms of monitoring means


Greater time to react and repair

F time

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FOBAS Engine
We receive some performance measurements from the engine: Standard engine performance data Temperatures/Pressures Scavenge air temperatures Fuel line temperatures and Viscotherm settings Shop Test Data Fuel Before Purifier & Engine Cylinder Lubricating Oil (New) System oil (New) and in service samples Cylinder Drain Oil (Scrape down oil) x X Cylinders

And generate a comprehensive report on the condition of the engine Cylinder Wear and Combustion Performance CLO Feed Rate Fuel Purifier Performance Etc.

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FOBAS ENGINE - Some of the result areas


Performance
Power Balance - Pmax Power Balance - Ptdc Power Balance - MIP Power Balance - Exhaust Temperature VIT & Fuel Pump Shop Test - Load Indic. Shop Test - Pmax Shop Test - Ptdc Shop Test - Pmax-Ptdc Shop Test - MIP Shop Test - Texh Shop Test T/C RPM Shop Test - Pscav Shop Test - Engine RPM

Combustion
Combustion Stability Late Combustion Acid Condensation Burning Lubricant Check Injectors Inspect Pistons

Wear
Cylinders Running In Liner Max Wear Liner Wear Rate Combustion - deposits Piston/Liner Abrasion Skirt Abrasion Stuffing Box Cat-fines Overall Ring Groove Blow By Water

Cylinder Drain Oil


System Oil Contamination Fuel Oil Contamination Alkaline Reserve Sludge Water Fuel Ash Unburnt Fuel Dilution Dispersancy Cat-fines Iron Tin Chromium

Power Balance - Pmax-Ptdc Early Combustion

Fuel
ISO Comparison Representative Cat-fines Water Sea Water Acid Condensation Vanadium Na:V Ratio MCR Temperature Purifiers

System Oil
Drain Contamination Lubrication Dispersant Reserve Unburnt Fuel Water Wear Particles

Turbo Charger
After Cooler In Air Receiver Performance

Lloyds Register: Marine

FOBAS ENGINE 8 Point Analysis Strategy


By individual analysis of the eight key elements

1. Fuel oil quality 2. Air cooler and scavenge air 3. Combustion performance 4. Cylinder oil feed rate 5. Cylinder drain oil condition 6. Liner and ring wear 7. System oil condition 8. Engine performance indicators

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Reports

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Achieving World Class Performance

With thanks to SKF Reliability - Client Needs Analysis

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Shortcut to example.pdf.lnk

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Savings Illustration

FOBAS Engine
Extended cylinder overhauls Optimised CLO feed rate

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Scavenge port inspection at 31,000 hours

g/kWh

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Too much Cylinder Oil

Calcium deposit

Calcium deposit causing rings to stick

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Too much Cylinder Oil


Calcium deposit causing bore polishing

Abrasion of piston skirt against the liner wall.

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Too much Cylinder Oil


Calcium deposit causing bore polishing

Abrasion of piston skirt against the liner wall.

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Too much Cylinder Oil - Skirt Abrasion


Deposits on piston top land will not be concentric. More deposits will form in way of flame path
Deposits on the top land cause misalignment

Piston Skirt forced against the liner

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Too much Cylinder Oil


Piston Overhauled in Hong Kong

MAN B&W 12 K90MC 66 hrs later in Singapore

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Faulty injection & Combustion


`

Poor atomisation. Injection and combustion abnormalities identified. Injector


`

Sulzer 10RTA96C

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Fuel Oil Viscosity and Temperature


Cooler engine room (especially during winter)
Extent of Temp differential depends on: 1.Engine room Temp 2.Quality of fuel oil line Insulation

Temperature Drop

Hot Purifier room some distance from the Main Engine

Lower temperature fuel at point of injection means poor atomisation and thus poor combustion.

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Poor Combustion Means More Wear

Values exclude engines during running-in period and catastrophic failures

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Better Combustion
`

Pistons become cleaner with good combustion and low feed

10,000 hours since overhaul (1.2g/bhph).

18,822 hours since overhaul (0.9 g/bhph)

Lloyds Register: Marine

Thanks

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