CYLINDER CONDITION

MAN Diesel A/S

2006/09/09

CIRCLE OF CYLINDER CONDITION

EXHAUST
VALVE

MAN Diesel A/S

2006/09/09

EXHAUST VALVE

MAN Diesel A/S

2006/09/09

EXELLENT CONDITION
36.400 HR

MAN Diesel A/S

2006/09/09

MAYBE NOT SO GOOD

MAN Diesel A/S

2006/09/09

CIRCLE OF CYLINDER CONDITION

EXHAUST VALVE

EXHAUST
GAS
BOILER
MAN Diesel A/S

2006/09/09

EXELLENT

MAN Diesel A/S

2006/09/09

HOT

MAN Diesel A/S

2006/09/09

HOT

MAN Diesel A/S

2006/09/09

EX. ROTOR

MAN Diesel A/S

2006/09/09

WHERE IS THE NOZZLE RING

MAN Diesel A/S

2006/09/09

OOPS.

MAN Diesel A/S

2006/09/09

CIRCLE OF CYLINDER CONDITION

EXHAUST VALVE
EXHAUST GAS BOILER

FUEL
PUMP/
INJECTOR
MAN Diesel A/S

2006/09/09

SLIDE FUEL VALVE

MAN Diesel A/S

2006/09/09

SLIDE FUEL VALVE

MAN Diesel A/S

2006/09/09

FUEL PUMP PLUNGER

3330187/20030423

(2160/KEA)

MAN Diesel A/S

2006/09/09

PIRATE PARTS

MAN Diesel A/S

2006/09/09

NON-0RIGINAL FUEL NOZZLES

MAN Diesel A/S

2006/09/09

EXPENSIVE CHEAP PARTS

MAN Diesel A/S

2006/09/09

TEST STAND?

MAN Diesel A/S

2006/09/09

CIRCLE OF CYLINDER CONDITION

EXHAUST VALVE
EXHAUST GAS BOILER
FUEL PUMP/
INJECTORS

FUEL OIL

MAN Diesel A/S

2006/09/09

 MAN Diesel A/S

2006/09/09

 MAN Diesel A/S

2006/09/09

 MAN Diesel A/S

2006/09/09

 MAN Diesel A/S

2006/09/09

 MAN Diesel A/S

2006/09/09

 MAN Diesel A/S

2006/09/09

 MAN Diesel A/S

2006/09/09

 MAN Diesel A/S

2006/09/09

 MAN Diesel A/S

2006/09/09

 MAN Diesel A/S

2006/09/09

CAT FINES

MAN Diesel A/S

2006/09/09

CORRECT TREATMENT

MAN Diesel A/S

2006/09/09

SCUFFING

Scuffing in 6 cylinders of 10K98MC-C due to fuel oil being polluted with polystyrene.
MAN Diesel A/S

2006/09/09

ABRASIVE WEAR

MAN Diesel A/S

2006/09/09

ABRASIVE WEAR

MAN Diesel A/S

2006/09/09

CIRCLE OF CYLINDER CONDITION

EXHAUST VALVE
EXHAUST GAS BOILER
FUEL PUMP/
INJECTORS

LINER

FUEL OIL

MAN Diesel A/S

2006/09/09

 MAN Diesel A/S

2006/09/09

 MAN Diesel A/S

2006/09/09

LOW WEAR RIDGE

MAN Diesel A/S

2006/09/09

Sulphur attack

MAN Diesel A/S

2006/09/09

SCUFFING AND COLD CORRSION

MAN Diesel A/S

2006/09/09

Cylinder Liner and Cylinder Frame

A: Previous design
Cold corrosion on cylinder
liners has been experienced
in some cases

B: New design
Cylinder liner

Using an uncooled cylinder

Frame, the temperature on the
running surface has been
increased in the lower part of
the cylinder liner by about 60C

Cylinder
frame uncooled

Good experience
The general cylinder condition
is improved

MAN Diesel A/S

2006/09/09

COLD CORROSION CLOVER LEAFING

CORRDED AREA
MINIMUM RING CONTACT
MAN Diesel A/S

2006/09/09

During combustion some SO2 is transformed to

SO3, which forms H2SO4 .In the shown

position the condensation can take place as

access to the running surface is possible
Position where the edge of top land starts to
uncovers the liner running surface

T e m p e ra tu re

Volume of scav. air, which do not participate in

the combustion process.
Liner temp. and Acid Dew Point 3%S

300
280
260
240
220
200
180
160
140
120
100

No condensation
0.1458

y = 129.99x

K90MC LTL
K90MC HTL
Power (3%Sulphur)

20

40

60
80
Presure [Bar]

100

MAN Diesel A/S

120

2006/09/09

140

Cold Corrosion
Neutralisation
controlling
cold orrosion:

How much to be
neutralised depends
on how much is
condensate

How much is
condensated,
depends on the liner
temperature

MAN Diesel A/S

2006/09/09

VARIOUS TYPE OF WEAR

Corrossive wear (cold corrosion)
Characteristics:

Local flame-like formations or belts of slightly more wear at cold areas of

the liner.

MAN Diesel A/S

2006/09/09

Cylinder Liner Running Surface

6
Ra

.3

9.4
Raa 1.6
R

Wave length
8 mm

50% remaining
wave cut
50% honed
plato

Wave length
8 mm

0.01-0.02 mm

Original wave cut standard

0.01-0.02 Original
0.04-0.05 Latest standard

Semi-honing
MAN Diesel A/S

2006/09/09

SURFACE ROUGHNESS

MAN Diesel A/S

2006/09/09

Engine manufacturers specification

This is an example of what a honing specification can look like.
These parameters are necessary information in order to achieve
the correct surface.

Ra = 0,8 1,5 m

Rmax= 6 10 m

Rz = 5 9 m

Mr = 70 90% at 3 m level

Liner taper = Max 0,7 mm

MAN Diesel A/S

2006/09/09

Ra = Arithmetical mean roughness

Ra is the area of material above the mean line and the area
of the air gap below divided with the number of
measurement points.

MAN Diesel A/S

2006/09/09

Rmax = Maximum Roughness Depth

Rmax is the evaluation line divided in five equal parts. In the
part with the lowest point the Rmax is the peak-to valley value.

MAN Diesel A/S

2006/09/09

Rz = Mean Peak-to-Valley Height

Rz is the average of single peak-to-valley heights of five
equal sampling lengths of the total evaluation length.

MAN Diesel A/S

2006/09/09

Mr = Material Ratio
Mr is the material ratio in % of the total evaluation
length measured at a certain depth.

MAN Diesel A/S

2006/09/09

Abbot curve
Note: current designation for tp is Mr
The picture shows an Abbot-Firestone curve, which is a
graph of Mr at different heights.

MAN Diesel A/S

2006/09/09

Surface profiles
High-lighting six different surface profiles with the same Rmax
five of them
with the
same Ra
and three
of them
with Mr
over 70 %,
but only
one of them
is suitable
as a honing
profile.

MAN Diesel A/S

2006/09/09

HMM

MAN Diesel A/S

2006/09/09

MAN Diesel A/S

2006/09/09

MAN Diesel A/S

2006/09/09

VARIOUS TYPE OF WEAR

Vertical stripes from port rips to mid-upper part of liner caused by
blow back (exh. Valve timing). Combustion particle storm
settles on piston rings at ports, while rings remain clean at rips.

MAN Diesel A/S

2006/09/09

Laquer formation Charcteristics

Chemical reaction between additives in cyl. oil and water
Settles on liner wall at holes, where the piston rings are not
touching

MAN Diesel A/S

2006/09/09

Cylinder Condition
the unmistakable smell of scuffing.

MAN Diesel A/S

2006/09/09

Cylinder Condition
the unmistakable smell of scuffing.

MAN Diesel A/S

2006/09/09

Cylinder Condition
the unmistakable smell of scuffing.

MAN Diesel A/S

2006/09/09

Scuffed Liner and Piston Ring

Surfaces

MAN Diesel A/S

2006/09/09

Cylinder Condition, Scuffing wear

Status
Scuffing is the result of break
down of the oil film, leading to
adhesive contact (metal to
metal contact), severe heat
development due to friction
(700 deg. C), friction welding of
the surfaces, subsequent
hardening of the surfaces
(white cast iron) and extremely
high wear rates.

6 mm liner wear in 100 to 300

hours is not unusual

November 2004

(Rolsted / 2300)

MAN Diesel A/S

2006/09/09

 MAN Diesel A/S

2006/09/09

Introduction to cylinder condition

Various types of wear
Abrasive wear
Characteristics:

Metal to metal contact generally in upper levels of the liner due to foreign
particles (e.g. cat fines)

Grinding effect by embedded particles in both liner & piston rings.

Wear pattern of liner: Mainly upper part, where velocity of piston rings is
low and pressure is high, TDC (and perhaps BDC) wear ridges

Piston ring grooves are typically worn out more quickly as well
Wear rate: TBO is reduced consierebly, in some cases less than 1000
running hours.

MAN Diesel A/S

2006/09/09

 Corrosive wear is depending on

Sulphur content in the fuel
Liner temperature and the actual cylinder pressure at corrosion point
Amount of neutralisation additives added with the cylinder oil, feed rate and
BN

High Corrosive Wear

Cylinder liner wear rates can be very high (0,4 mm/1000 hrs.), without any
bad effects

apart from wear.

Low Corrosive wear

The risk of bore polish, is strongly increased, and scuffing occurs in many
cases

MAN Diesel A/S

2006/09/09

 MAN Diesel A/S

2006/09/09

NO NO

MAN Diesel A/S

2006/09/09

The Angle Grinder must never be used!

MAN Diesel A/S

2006/09/09

TALCUM POWDER TEST

MAN Diesel A/S

2006/09/09

HAMMERING MARKS OF
BROKEN PISTON RINGS

MAN Diesel A/S

2006/09/09

 MAN Diesel A/S

2006/09/09

PISTON CLEANING RING

Cylinder cover
Piston high topland

Piston cleaning ring

Cylinder liner

MAN Diesel A/S

2006/09/09

 MAN Diesel A/S

2006/09/09

Piston top kollision with PC ring in top of

liner due to scuffed cyl liner.

PXN 2300

MAN Diesel A/S

2006/09/09

CYLINDER CONDITION

MAN Diesel A/S

2006/09/09

CIRCLE OF CYLINDER CONDITION

EXHAUST VALVE

PISTON/
PISTON

EXHAUST GAS BOILER

FUEL INJECTORS
FUEL OIL
LINER

RINGS
MAN Diesel A/S

2006/09/09

 MAN Diesel A/S

2006/09/09

 MAN Diesel A/S

2006/09/09

Piston Cooling Insert

3333420.2006.04.05

(2300/SBJ)

MAN Diesel A/S

2006/09/09

TEMP. ON GAS SIDE LOWER 20 C

3333293.2005.01.18

(2500/MCJ)

MAN Diesel A/S

2006/09/09

NEW STYLE PISTON

MAN Diesel A/S

2006/09/09

MAXIMUM MEASURED COMBUSTION

CHAMBER TEMPERATURES

436

639
465

185

225

567 394
392 379
198

196

MAN Diesel A/S

2006/09/09

COMBUSTION CHAMBER

Narrow combustion
volume

Large combustion
volume

MAN Diesel A/S

2006/09/09

HEAT LOAD ON PISTON

Previous piston design

Oros piston design

MAN Diesel A/S

2006/09/09

Gas Temperature 18 ms After

Start of Fuel Injection
Gas Temperature 18 ms After
Start of Fuel Injection

Temperature
deg. Cel.
2200
2100
2000
1900
1800
1700
1600
1500
1400
1300
1200
1100
1000
900
800

Original combustion chamber

New combustion chamber

MAN Diesel A/S

2006/09/09

 MAN Diesel A/S

2006/09/09

 MAN Diesel A/S

2006/09/09

 MAN Diesel A/S

2006/09/09

CYLINDER CONDITION

MAN Diesel A/S

2006/09/09

CYLINDER CONDITION

MAN Diesel A/S

2006/09/09

 7S80MC
Running hours: 5,098

MAN Diesel A/S

2006/09/09

Upper ring groove worn out

K90MC
6831
Running
Hours

MAN Diesel A/S

2006/09/09

Induction Heating of Tungsten

Carbide

MAN Diesel A/S

2006/09/09

Laser Sintering K90 Test Piston

MAN Diesel A/S

2006/09/09

Deposition of Tungsten Carbide (WC) in

Piston Ring Groove by HVOF

MAN Diesel A/S

2006/09/09

Radial direction

Wear Traces in Chromium Layer

Micro crack pattern in Cr layer (225x)

SEM photo (157x)

Detail (780x)

Detail (780x)

MAN Diesel A/S

2006/09/09

PISTON PROBLEM

MAN Diesel A/S

2006/09/09

PISTON PROBLEM

Ghent, July 2005

H. Rolsted

MAN Diesel A/S

2006/09/09

Cylinder Condition

MAN Diesel A/S

2006/09/09

????

MAN Diesel A/S

2006/09/09

Oros Piston and Piston Ring

Ring pack

1st ring: Type: CPR

with Alu-Coat
High
2nd ring: Type: RM5, oblique cut
with Alu-Coat
Low
3rd ring: Type: RM5, oblique cut
with Alu-Coat
Low
4th ring: Type: RM5, oblique cut
with Alu-Coat
Low

MAN Diesel A/S

2006/09/09

 MAN Diesel A/S

2006/09/09

Ruined piston ring surface.

MAN Diesel A/S

2006/09/09

 MAN Diesel A/S

2006/09/09

Scuffing

Characteristics:

Metal to metal contact due to oil film

disturbances
Welding/tearing off of materials from both
liner & piston rings
Wear pattern of liner: All running surface,
TDC and BDC wear ridges
Piston ring grooves are typically worn out
more quickly as well
Wear rate: Total wear out within days
MAN Diesel A/S

2006/09/09

6S90MC ~ 8.300 Hours

MAN Diesel A/S

2006/09/09

ALCU COATED CPR RING

MAN Diesel A/S

2006/09/09

Piston Rings
Broken K98 piston ring,
original type

Piston crown on K98MC-C

Broken top ring, 2nd and 3rd
ring collapsed
MAN Diesel A/S

2006/09/09

Orginal CL Groove Locations

Predominant breakage location

MAN Diesel A/S

2006/09/09

Service Experience

Stress concentration (bending),

left 2 mm CL groove: 100%,
right 3 mm CL groove: 72%

Result of fatigue testing: Relative safety factors

Original type:
E-type:
E4-type:

1.0 (100%)
1.4 (140%)
2.1 (210%)
MAN Diesel A/S

2006/09/09

ABRASIVE WEAR
Status

Problem

Cat fines in fuel:

Severe wear of liners
Severe wear of rings
Wear out of CL-grooves
Scuffing

MAN Diesel A/S

2006/09/09

ABRASIVE WEAR
Status

Cat-fines embedded in piston ring

running surface

MAN Diesel A/S

2006/09/09

 MAN Diesel A/S

2006/09/09

Piston Ring with White Layer

Status

3333685.2006.03.25

(2300/SBJ)

MAN Diesel A/S

2006/09/09

TIME FOR OVERHAUL

MAN Diesel A/S

2006/09/09

TIME FOR OVERHAUL

MAN Diesel A/S

2006/09/09

TIME FOR OVERHAUL

MAN Diesel A/S

2006/09/09

5 year's TBO on Large Bore Engines

Backed up by the service experience?

K98MC
First time overhaul unit
1 at 42,250 hours.
Note, still very good
piston ring condition

MAN Diesel A/S

2006/09/09

5 year's TBO on Large Bore Engines

Backed up by the service experience?

10K90MC-C
45,975 hours
since previous
overhaul. Toppiston ring PM2+
Ni-Gr
(58,500 engine hours)

MAN Diesel A/S

2006/09/09

5 year's TBO on Large Bore Engines

Backed up by the service experience?

10K90MC-C
45,975 hours
since previous
overhaul. Toppiston ring PM2+
Ni-Gr
(58,500 engine hours)

MAN Diesel A/S

2006/09/09

K90MC PISTON CROWN CRACK

MAN Diesel A/S

2006/09/09

Scuffing, experience and countermeasures.

Reasons for scuffing
Reasons for the actual increase in scuffing
cases on large bore:
Bore polish as a consequence of a surplus of alkali
additives

Broken down oil film as a result of too rapid load

changes

Water ingress due to inefficient water separation

Cat fines, wear our of the CL grooves / broken rings
Piston ring design
6CL E6 E4 30/60 E4Cr 30/60
Base material increased wear changed
pressure distribution

Material (ring/liner) tribological scuffing

resistance

MAN Diesel A/S

2006/09/09

Scuffing, experience and countermeasures.

New Piston Ring Standard

Note, embedded iron into the

alucoat of ring 2 and 3 after
test bed running

MAN Diesel A/S

2006/09/09

Scuffing, experience and countermeasures.

New Piston Ring Standard

PM2/Ni-Gr/Cr ring package.

Note, embedded iron into the
alu-coat of ring 2 and 3 after
sea trail

MAN Diesel A/S

2006/09/09

R29VM/RF2312/RF3310/Cr

R47 / Alucoat / Cr

R47 / Alucoat

R47 / RF2312/RF3310

Top:

2nd :

3rd :

4th:

SH 265 Cylinder 1:

Scuffing, experience and countermeasures.

New Piston Ring Standard

Annual meeting, Autumn 2006,

H. Rolsted

MAN Diesel A/S

2006/09/09

Scuffing, experience and countermeasures.

New Piston Ring Standard

SH 265 Cylinder 1:
Top:

R29VM/RF2312/RF3310/Cr

2nd :

R47 / Alucoat / Cr

3rd :

R47 / Alucoat

4th:

R47 / RF2312/RF3310

Annual meeting, Autumn 2006,

H. Rolsted

MAN Diesel A/S

2006/09/09

R29VM/RF2312/RF3310/Cr

R47 / Alucoat / Cr

R47 / Alucoat

R47 / RF2312/RF3310

Top:

2nd :

3rd :

4th:

SH 265 Cylinder 1:

Scuffing, experience and countermeasures.

New Piston Ring Standard

3rd ring

4th ring

Annual meeting, Autumn 2006,

H. Rolsted

MAN Diesel A/S

2006/09/09

R47 / Alucoat / Cr

R47 / Alucoat

R47 / RF2312/RF3310

2nd :

3rd :

4th:

4th r
ing

R29VM/RF2312/RF3310/Cr
Top:

SH 265 Cylinder 1:

Scuffing, experience and countermeasures.

New Piston Ring Standard

Annual meeting, Autumn 2006,

H. Rolsted

MAN Diesel A/S

2006/09/09

RVK-C / PM2 / Ni Gr / Cr

RM5 / Alucoat / Cr

RM5 / Alucoat

RM5 / PM2 / Ni - Gr

Top:

2nd :

3rd :

4th:

SH 265 Cylinder 12:

Scuffing, experience and countermeasures.

New Piston Ring Standard

Annual meeting, Autumn 2006,

H. Rolsted

MAN Diesel A/S

2006/09/09

Scuffing, experience and countermeasures.

New Piston Ring Standard

PM2/Alucoat/Cr ring package

mounted to cylinder 6.
Inspected at 230 hours. Note
the PM2 is just about being
exposed:

Annual meeting, Autumn 2006,

H. Rolsted

MAN Diesel A/S

2006/09/09

Scuffing, experience and countermeasures.

New Piston Ring Standard

PM5 / Alucoat, cyl 9

2046 hours in new liner and new piston

Annual meeting, Autumn 2006,

H. Rolsted

MAN Diesel A/S

2006/09/09

Scuffing, experience and countermeasures.

New Piston Ring Standard

Annual meeting, Autumn 2006,

H. Rolsted

MAN Diesel A/S

2006/09/09

Scuffing, experience and countermeasures.

New Piston Ring Standard

Annual meeting, Autumn 2006,

H. Rolsted

MAN Diesel A/S

2006/09/09

Large Bore piston ring standard

Previous standard:
0.1 mm Nickel-Graphite
running-in coating

Present standard:
1st ring:
Cl-grooves:
Base material :
Hard coating:
Run-in coating:
Bottom face:

CPR E4-180
Vermicular cast, CV1
0.5mm Cermet (PM2)
0.1mm
Chrome plating

0.1 mm Alucoat
running-in coating

2nd ring:
Left cut
Base material : Grey cast, CF5
Run-in coating: 0.3mm Alucoat
Bottom face:
Chrome plating

3rd ring:
Right cut
Base material : Grey cast, CF5
Run-in coating: 0.3mm Alucoat

0.1 mm Nickel-Graphite
running-in coating

4th ring:
Left cut
Base material : Grey cast, CF5
Hard coating:
0.3mm Cermet
(PM2)
Run-in coating: 0.1mm

0.1 mm Alucoat
running-in coating

MAN Diesel A/S

2006/09/09

Large Bore piston ring standard

Annual meeting, Autumn 2006,

H. Rolsted

MAN Diesel A/S

2006/09/09

Requirements for good piston

performance
Correct running in procedure.

Sudden load changes must be avoided.

Even load distribution on all units.
Differential pressure between Pmax and Pcomp to be less then 32 bar.
Suffcient amount of clean air.
Water mist catcher and drain must work to avoid water splash on the liner
wall, which will ruin the oil film.
ALPHA lub system will reduce the cylinder oil consupmtion and avoid
overlubrication.
The correct amount of cylinder oil is needed for the Sulphur content.
Ring grooves must be clean and within size limits.
Slide Fuel Valves will minimize the carbon deposits in the ring grooves.
Optimal atomization of injected fuel without after dripping.
Scavenge space to be kept clean by drainage and manual cleaning.
Running in
MAN Diesel A/S

2006/09/09

CIRCLE OF CYLINDER CONDITION

EXHAUST VALVE
EXHAUST GAS BOILER
FUEL INJECTORS

TURBO

FUEL OIL
LINER

CHARGER

PISTON RINGS

MAN Diesel A/S

2006/09/09

COMPLIMENTS FROM ABB

MAN Diesel A/S

2006/09/09

Cylinder Condition
13,000 tons Nitrogen
2,000 tons Oxygen

12K98ME

860 tons CO2

350 tons H2O

Fuel oil 250 tons

16 tons SO2

Sulphur 8 tons

1/4 tons H2SO4

Ai

s
on
t
0

.5
ns
to

Stroke: 2.66 meter

l1
oi

Bore: 0.98 meter

r
de
lin
Cy

s
ton
0
0
0
3.0 3.00
n
1
e
yg en
Ox itrog
N

,00
5
1

Speed: 94 rpm
Output: 93,360 Bhp / 68,640 kW
Piston speed: 8.3 m/sec

Cylinder Condition, the result of gigantic thermoand chemical reactions

MAN Diesel A/S

2006/09/09

CIRCLE OF CYLINDER CONDITION

EXHAUST VALVE
EXHAUST GAS BOILER

AIR
COOLERS

FUEL INJECTORS
FUEL OIL
LINER
PISTON RINGS
TURBO CHARGER

MAN Diesel A/S

2006/09/09

 MAN Diesel A/S

2006/09/09

 MAN Diesel A/S

2006/09/09

 MAN Diesel A/S

2006/09/09

 MAN Diesel A/S

2006/09/09

 MAN Diesel A/S

2006/09/09

6S90MC ENGINE
~ 8.300 Hours

MAN Diesel A/S

2006/09/09

CIRCLE OF CYLINDER CONDITION

EXHAUST VALVE
EXHAUST GAS BOILER
FUEL INJECTORS

AIR

FUEL OIL

QUALITY

LINER
PISTON RINGS
TURBO CHARGER

AIR COOLER
MAN Diesel A/S

2006/09/09

CYLINDER CONDITION

CORRECT AMOUNT OF AIR

NO EXTRA HOLES IN THE
AIR DUCTS
AIMED AT THE TURBOCHARGERS

MAN Diesel A/S

2006/09/09

CLEAN AIR?

MAN Diesel A/S

2006/09/09

 MAN Diesel A/S

2006/09/09

 MAN Diesel A/S

2006/09/09

STAY TUNED

MAN Diesel A/S

2006/09/09