Wear loaded components in large ship diesel engines - F M V · Wear loaded components in large ship diesel engines ... MAN Diesel & Turbo Diesel Engine Programme from 450 kW to 87

FMV Temadag om slid / 2012-11-15 1 < > MAN Diesel & Turbo

Wear loaded components

in large ship diesel engines

Jesper Vejlø Carstensen

MAN Diesel & Turbo Copenhagen

Material Technology & Research


Outline

Short company presentation

Two-stroke diesel engine overview

Combustion chamber parts

– piston rings

– piston crown

– exhaust valve spindle

Fuel pump parts

– heavy fuel oil

– bio fuel oil

Company presentation Engine overview Combustion chamber parts Fuel pump parts


MAN Diesel & Turbo Two-Stroke Head Office in Copenhagen

Employees (2011-12-31) : 1,295

2-Stroke Engine

Design

Products Engine Components

Spare Parts

PrimeServ

After Sales Service

2-Stroke Engine

Components

PrimeServ

Academy

2-Stroke Engine

Spare Parts



MAN Group Corporate Structure

Revenue ‘11:

€0.4 bn

Power Engineering Business

area

Division

Commercial Vehicles

MAN

Truck & Bus

Employees ‘11: 34,000

Revenue ‘11: €9.0 bn

MAN

Latin America



MAN SE

The MAN Group in 2011: €16.5 billion revenue - 52,500 employees

MAN

Diesel & Turbo



RENK (76%)



MAN Diesel & Turbo Areas of Activity

2-stroke and 4-stroke engines for marine and

stationary applications

Complete propulsion packages

Compressors and turbines for all industrial applications

Chemical reactors and apparatuses

Turnkey power plants

Operation and maintenance of power plants

(MAN | PowerManagement)

After Sales Services like repair, spare part supply,

retrofitting, recycling and monitoring of all MAN large-

bore engines and turbomachinery in use across the

world (MAN│PrimeServ)



MAN Diesel & Turbo Worldwide No. 1 Supplier of Two-stroke Diesel Engines



MAN Diesel & Turbo Diesel Engine Programme from 450 kW to 87 MW



MAN Diesel & Turbo Licensees Reported Order Books (Two-Stroke)



MAN Diesel & Turbo Market Share (Two-Stroke)

84%

14%

2% LOW SPEED ORDER BOOK ULTIMO JANUARY 2012

MAN B&W

Wärtsilä

Mitsubishi



Two-stroke Diesel Engine Overview

Exhaust

receiverExhaust

valve

Piston

crown

Turbo-

charger

Scavenge

ports

Piston

rod

Crosshead

Connecting

rod Crankshaft

Combustion

chamber

A-frame

Bottom

frame

Water mist

catcher

12S90ME-C9:

Dry mass: 2,070 t

Height: 14.5 m – Length: 24.2 m

Bore diameter: 0.9 m – Stroke: 3.3 m



Two-stroke Diesel Engine Combustion Chamber Parts

Exhaust valve (spindle)

Fuel injection valve

Piston (crown)

Cylinder cover

Cylinder liner



Combustion Chamber Parts Piston Crown, Rings and Skirt

Bore cooled

piston crown

Piston ring pack

Piston skirt



Combustion Chamber Parts Piston Rings - Cast Iron

surface after polishing surface after etching

Chatoyant phase = pearlite

White phase = cementite

Light grey phase = ferrite

Black phase = graphite



Combustion Chamber Parts Piston Rings - Cast Iron

surface after polishing

surface after etching

graphite

pearlite

cementite

pearlite

pearlite



Combustion Chamber Parts Piston Rings and Cylinder Liner

Cylinder liner Piston ring

Acid from gas phase dissolves in oil

Balance between neutralisation and

adsorption ("wetting") of liner/ring

Amount of corrosion depends on:

TBN, oil feed rate, neutralisation rate

graphite

pearlite

cementite

Neutralisation

Wetting/corrosion

SO3

H2O



Combustion Chamber Parts Lube Oil Dosage

Minimum oil dosage to maintain

hydrodynamic oil film



Grey cast iron base material

Alu-coating

Combustion Chamber Parts Piston Ring Pack

1st ring

2nd ring

3rd ring

4th ring

Vermicular cast iron base material

Chrome-plated bottom face

Cermet coating 0.5 mm

Alu-coat for running-in 0.1 mm


Chrome-plated bottom face

Alu-coating


Cermet coating 0.3 mm

Alu-coat for running-in 0.1 mm

Hard Coat / Soft Coat Ring Package



Combustion Chamber Parts Plasma Spraying of Piston Ring Pack

An inert gas is injected into an arc chamber

framed by two concentric water-cooled electrodes

(cathode and anode), ionizing the gas and

creating temperatures up to 30,000°C.

The gas expands and rushes from the torch as an

ionized "plasma". A powder feedstock is injected

into the plasma gas stream where it melts and is

spray-cast upon the substrate surface.

(W)

(Cu)



Combustion Chamber Parts Plasma Sprayed Coatings on Piston Ring

Alu-coat

Cermet

Base

material



Combustion Chamber Parts Piston Crown

Cross section of piston crown

with piston rings (red) Piston ring grooves with

hardchrome coating

(hardness 900 HV)



Combustion Chamber Parts Piston Crown – Ring Groove Wear

Worn off layer

Demand for increased performance

and compact design

increased wear



Combustion Chamber Parts Particles in Worn Ring Groove

50 µm

exposed

base material

hardchrome



Combustion Chamber Parts Particles in Worn Ring Groove

EDX mapping

blue = Cr

green = Al

red = Si

yellow = Al-Si

EDX mapping

blue = Fe

green = Al

red = Si

yellow = Al-Si



Combustion Chamber Parts Cat-fines in Heavy Fuel Oil

Diesel oil used for ship propulsion is so-called heavy fuel or bunker oil, which is the

heaviest distillate from the refining of raw oil. The quality varies substantially.

Catalyst particles are used to crack the oil. These are Al-Si rich particles with a

large pore volume and large amounts of chemically bound water.

Thermal and mechanical decomposition of catalyst particles Cat-fines

MxDy(Alx+2ySin-x-2yO2n) · mH2O

M=Na+, K+

D=Ca2+, Mg2+



Combustion Chamber Parts Fuel Oil System

Service

Tank

(day) 35°C

Service

Tank

(day) 90°C

Centrifuge(s) (40°C)

Centrifuge(s)

(95 - 100°C)

HFO Supply

pump HFO Circulating

pump

If unifuel system

To Gensets

MDO Storage Tank (25°C)

S e

t t l i n g

T a n

k (

2 5

° C )

S e

t t l i n

g

a n k 1

( 6

0 ° C

)

Bunker Storage Tank 1 (45°C)



S e

t t l i n g

a n

k 2

( 6 0

° C )

T

T

Sep

ara

tion

effic

ien

cy

vs

.

vis

co

sity

0,0

50,0

10

0,0

150

,0

Vis

co

sity

(cS

t)Sep. efficiency (%)

Se

pa

ratio

n e

fficie

nc

y v

s. te

mp

era

ture

0

10

20

30

40

50

60

70

80

90

100

40

50

60

70

80

90

100

Te

mp

era

ture

(dg

r C)

Separation efficiency

gD

l

ls

18

)(

v2

g

Sep

ara

tion

effic

ien

cy

vs

.

vis

co

sity

0,0

50,0

10

0,0

150

,0

Vis

co

sity

(cS


Se

pa

ratio

n e

fficie

nc

y v

s. te

mp

era

ture

0

10

20

30

40

50

60

70

80

90

100

40

50

60

70

80

90

100

Te

mp

era

ture

(dg

r C)


Sep

ara

tion

effic

ien

cy

vs

.

vis

co

sity

0,0

50,0

10

0,0

150

,0

Vis

co

sity

(cS


Se

pa

ratio

n e

fficie

nc

y v

s. te

mp

era

ture

0

10

20

30

40

50

60

70

80

90

100

40

50

60

70

80

90

100

Te

mp

era

ture

(dg

r C)


gD

l

ls

18

)(

v2

g

dirty oil feed

clean oil

discharge

solids

discharge

water

discharge

HFO

MDO



Combustion Chamber Parts Ring Groove Wear Mechanisms

Oil Hard chrome

Vertical movement of ring

results in impact loads

Rotation of

ring results in

sliding wear

Horizontal movement

results in abrasive wear Ring

Abrasive



Combustion Chamber Parts Ring Groove Wear – Preliminary Solution

Hard chrome on

piston ring underside

Hard chrome

Oil Hard chrome

Abrasive

Ring

abrasive wear

is minimized



Combustion Chamber Parts Ring Groove Wear – Long Term Solution

Laser cladded cermet coating

with coarse tungsten carbides.

Carbide amount: 60-75 vol%

Carbide size: 45-160 µm

Carbide hardness: 3-4000 HV



Combustion Chamber Parts Exhaust Valve – Spindle Guide

Exhaust valve spindle guide – nitrocarburized grey cast iron



Combustion Chamber Parts Exhaust Valve – HVOF Coating on Spindle Stem

HVOF coating consisting of Cr3C2 in a matrix of NiCr

as replacement for hard chrome



Combustion Chamber Parts Exhaust Valve – HVOF Coating on Spindle Stem



Combustion Chamber Parts Exhaust Valve – Spindle Disc

Service temperature

profile of spindle disc

Impact on valve seat area

combined with high service

temperature and corrosive

environment

Nimonic 80A



Combustion Chamber Parts Exhaust Valve - DuraSpindle

GMAW of

Inconel 718

Austenitic

stainless

valve steel

Rolling process,

10 t load

Age hardening

heat treatment




Welding of DuraSpindle

hardfacing (Inconel 718)




Rolling depth

1st groove 2nd groove 3rd groove

Rolling of DuraSpindle





24 hrs

720oC / 8 hrs 620oC / 6 hrs

Hardening of DuraSpindle


by 2-stage heat treatment




Inconel 718

Ni-Cr-W

valve steel

Potential cost saving is 100.000 DKK

for a K98ME-C exhaust valve

S60MC Nimonic spindle, 25.500 service hrs S60MC DuraSpindle, 33.900 service hrs

Seat hardness: 400 HV Seat hardness: 550-600 HV



Fuel Pump Parts Plunger and Barrel

Barrel

Plunger



Fuel Pump Parts Plunger and Barrel

Plasma nitrided

Cr-Al alloyed steel

Nitrided case: min. 0.4 mm

Surface hardness: 900-1100 HV



Fuel Pump Parts Plunger and Barrel - Scuffing

Scuffing

on plunger

and barrel



Fuel Pump Parts Plunger –PVD Coated

C WC/C (a-C:H:W)

BALINIT® C, with its low coefficient of

friction and good sliding properties, is

deployed mainly to reduce adhesive wear

(scuffing, seizing, cold-welding) and can

also withstand high loads at deficient

lubrication or dry running.

New standard for 4-stroke

Not (yet) implemented in 2-stroke



Fuel Pump Parts Bio Fuel Applications

Mouscron, December 2006

17.6 MW Power plant

18V48/60 4-Stroke engine

Refined plant oil



Fuel Pump Parts Bio Fuel Applications

Wieze, September 2008

35 MW Power plant

2 x 18V48/60 4-Stroke engines

Refined plam oil (stearine)

1/3 goes to chocolate production

while the rest is sold to the private

supply network (60.000 households)



Fuel Pump Parts Bio Fuel Properties

Rape

seed oil Palm oil Fish oil

McDonald

frying oil Tallow

HFO

(ref.)

Density

at 15 C Kg/m3 921 915 926 923 917 977

Heat of

combustion MJ/kg 36,89 36,87 36,60 36,85 36,81 39,82

Viscosity

at 100 C cSt 7,88 8,33 7,23 11,30 7,41 32,27

Carbon Mass% 77,7 76,6 77,5 77,2 77,4 86,8

Nitrogen Mass% 1 < 0,1 0,1 < 0,05 < 0,05 0,4

Sulfur Mass% < 0,05 0,007 < 0,05 < 0,1 < 0,05 0,93

Total Acid

Number

(TAN)

Mg KOH/g 2,4 11,0 13,1 3,9 40,5 < 1



Fuel Pump Parts Refining Bio Fuels

The distillative deacidification is a steam distillation

The principal task of the steam treatment is to

remove free fatty acids (reduce TAN to max. 4)



Fuel Pump Parts Standard Plunger with Crude Palm Oil

Fuel pump plunger

(nitrided steel) after

operation with crude

palm oil for 1000 hrs.

(TAN 12, un-refined)



Fuel Pump Parts Standard Plunger with Crude Palm Oil

Timewise progress

1. Intercrystalline attack

2. Grains fall out

3. General corrosion

Nitrided steel stored in crude palm oil

for 500 hrs (top) and 2000 hrs (bottom)



Fuel Pump Parts Standard Plunger with Tallow

Fuel pump plunger (nitrided steel) after operation with tallow for 200 hrs (TAN 46, unrefined)



Fuel Pump Parts Bio Fuel Tests on Fuel Pump Test Rig

Engine type: 90MC-C

Fuel type: Crude palm oil

Running hours: 200 hrs Drain

High pressure fuel

Atmospheric air

Highpressurefuel to fuel valve

Fuel pump barrel

Lube hole

Fuel pump plunger

Fuel inlet

Fuel pump housing

Low pressure fuel

Suction valve

Fuel pump top cover

Puncture valvehigh pressure

Piston for puncture valve

Drain

3 tests run with different

sets of plunger and barrel:

1. Nitrided steel (ref.)

2. X90CrMoV18

3. HS 6-5-2

Steel C% Cr% W% Mo% V%

X90CrMoV18 0.9 18 - 1 0.1

HS 6-5-2 0.9 4 6 5 2



Fuel Pump Parts Two-Stroke Engine Operating on Bio Fuel

MAN B&W 7L35MC-S engine Power plant site from PBB GmbH in Brake, Germany

Engine: supplying 4.2 MW to the national grid and 3.6 MW to a palm-oil refinery situated nearby.

Fuel: Crude palm oil with a Total Acid Number (TAN) of up to 15 mg/KOH/g.




Larger fuel valves

Introduced

Reinforced camshaft

Introduced

Larger fuel pumps

introduced;

modified materials




Cylinder liner Piston ring

graphite

pearlite

cementite



Thank you for your attention


All data provided in this document is non-binding.

This data serves informational purposes only and is especially

not guaranteed in any way. Depending on the subsequent

specific individual projects, the relevant data may be subject

to changes and will be assessed and determined individually

for each project. This will depend on the particular

characteristics of each individual project, especially specific

site and operational conditions.

Disclaimer

Documents

Wear loaded components in large ship diesel engines - F M V · Wear loaded components in large ship diesel engines ... MAN Diesel & Turbo Diesel Engine Programme from 450 kW to 87