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
FMV Temadag om slid / 2012-11-15 2 < > MAN Diesel & Turbo
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
FMV Temadag om slid / 2012-11-15 3 < > MAN Diesel & Turbo
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
Company presentation Engine overview Combustion chamber parts Fuel pump parts
FMV Temadag om slid / 2012-11-15 4 < > MAN Diesel & Turbo
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
Employees ‘11: 2,000
Revenue ‘11: €3.6 bn
MAN SE
The MAN Group in 2011: €16.5 billion revenue - 52,500 employees
MAN
Diesel & Turbo
Employees ‘11: 14,000
Revenue ‘11: €3.6 bn
RENK (76%)
Company presentation Engine overview Combustion chamber parts Fuel pump parts
FMV Temadag om slid / 2012-11-15 5 < > MAN Diesel & Turbo
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)
Company presentation Engine overview Combustion chamber parts Fuel pump parts
FMV Temadag om slid / 2012-11-15 6 < > MAN Diesel & Turbo
MAN Diesel & Turbo Worldwide No. 1 Supplier of Two-stroke Diesel Engines
Company presentation Engine overview Combustion chamber parts Fuel pump parts
FMV Temadag om slid / 2012-11-15 7 < > MAN Diesel & Turbo
MAN Diesel & Turbo Diesel Engine Programme from 450 kW to 87 MW
Company presentation Engine overview Combustion chamber parts Fuel pump parts
FMV Temadag om slid / 2012-11-15 8 < > MAN Diesel & Turbo
MAN Diesel & Turbo Licensees Reported Order Books (Two-Stroke)
Company presentation Engine overview Combustion chamber parts Fuel pump parts
FMV Temadag om slid / 2012-11-15 9 < > MAN Diesel & Turbo
MAN Diesel & Turbo Market Share (Two-Stroke)
84%
14%
2% LOW SPEED ORDER BOOK ULTIMO JANUARY 2012
MAN B&W
Wärtsilä
Mitsubishi
Company presentation Engine overview Combustion chamber parts Fuel pump parts
FMV Temadag om slid / 2012-11-15 10 < > MAN Diesel & Turbo
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
Company presentation Engine overview Combustion chamber parts Fuel pump parts
FMV Temadag om slid / 2012-11-15 11 < > MAN Diesel & Turbo
Two-stroke Diesel Engine Combustion Chamber Parts
Exhaust valve (spindle)
Fuel injection valve
Piston (crown)
Cylinder cover
Cylinder liner
Company presentation Engine overview Combustion chamber parts Fuel pump parts
FMV Temadag om slid / 2012-11-15 12 < > MAN Diesel & Turbo
Combustion Chamber Parts Piston Crown, Rings and Skirt
Bore cooled
piston crown
Piston ring pack
Piston skirt
Company presentation Engine overview Combustion chamber parts Fuel pump parts
FMV Temadag om slid / 2012-11-15 13 < > MAN Diesel & Turbo
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
Company presentation Engine overview Combustion chamber parts Fuel pump parts
FMV Temadag om slid / 2012-11-15 14 < > MAN Diesel & Turbo
Combustion Chamber Parts Piston Rings - Cast Iron
surface after polishing
surface after etching
graphite
pearlite
cementite
pearlite
pearlite
Company presentation Engine overview Combustion chamber parts Fuel pump parts
FMV Temadag om slid / 2012-11-15 15 < > MAN Diesel & Turbo
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
Company presentation Engine overview Combustion chamber parts Fuel pump parts
FMV Temadag om slid / 2012-11-15 16 < > MAN Diesel & Turbo
Combustion Chamber Parts Lube Oil Dosage
Minimum oil dosage to maintain
hydrodynamic oil film
Company presentation Engine overview Combustion chamber parts Fuel pump parts
FMV Temadag om slid / 2012-11-15 17 < > MAN Diesel & Turbo
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
Grey cast iron base material
Chrome-plated bottom face
Alu-coating
Grey cast iron base material
Cermet coating 0.3 mm
Alu-coat for running-in 0.1 mm
Hard Coat / Soft Coat Ring Package
Company presentation Engine overview Combustion chamber parts Fuel pump parts
FMV Temadag om slid / 2012-11-15 18 < > MAN Diesel & Turbo
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)
Company presentation Engine overview Combustion chamber parts Fuel pump parts
FMV Temadag om slid / 2012-11-15 19 < > MAN Diesel & Turbo
Combustion Chamber Parts Plasma Sprayed Coatings on Piston Ring
Alu-coat
Cermet
Base
material
Company presentation Engine overview Combustion chamber parts Fuel pump parts
FMV Temadag om slid / 2012-11-15 20 < > MAN Diesel & Turbo
Combustion Chamber Parts Piston Crown
Cross section of piston crown
with piston rings (red) Piston ring grooves with
hardchrome coating
(hardness 900 HV)
Company presentation Engine overview Combustion chamber parts Fuel pump parts
FMV Temadag om slid / 2012-11-15 21 < > MAN Diesel & Turbo
Combustion Chamber Parts Piston Crown – Ring Groove Wear
Worn off layer
Demand for increased performance
and compact design
increased wear
Company presentation Engine overview Combustion chamber parts Fuel pump parts
FMV Temadag om slid / 2012-11-15 22 < > MAN Diesel & Turbo
Combustion Chamber Parts Particles in Worn Ring Groove
50 µm
exposed
base material
hardchrome
Company presentation Engine overview Combustion chamber parts Fuel pump parts
FMV Temadag om slid / 2012-11-15 23 < > MAN Diesel & Turbo
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
Company presentation Engine overview Combustion chamber parts Fuel pump parts
FMV Temadag om slid / 2012-11-15 24 < > MAN Diesel & Turbo
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+
Company presentation Engine overview Combustion chamber parts Fuel pump parts
FMV Temadag om slid / 2012-11-15 25 < > MAN Diesel & Turbo
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)
Bunker Storage Tank 2 (45°C)
Bunker Storage Tank 3 (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
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
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
dirty oil feed
clean oil
discharge
solids
discharge
water
discharge
HFO
MDO
Company presentation Engine overview Combustion chamber parts Fuel pump parts
FMV Temadag om slid / 2012-11-15 26 < > MAN Diesel & Turbo
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
Company presentation Engine overview Combustion chamber parts Fuel pump parts
FMV Temadag om slid / 2012-11-15 27 < > MAN Diesel & Turbo
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
Company presentation Engine overview Combustion chamber parts Fuel pump parts
FMV Temadag om slid / 2012-11-15 28 < > MAN Diesel & Turbo
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
Company presentation Engine overview Combustion chamber parts Fuel pump parts
FMV Temadag om slid / 2012-11-15 29 < > MAN Diesel & Turbo
Combustion Chamber Parts Exhaust Valve – Spindle Guide
Exhaust valve spindle guide – nitrocarburized grey cast iron
Company presentation Engine overview Combustion chamber parts Fuel pump parts
FMV Temadag om slid / 2012-11-15 30 < > MAN Diesel & Turbo
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
Company presentation Engine overview Combustion chamber parts Fuel pump parts
FMV Temadag om slid / 2012-11-15 31 < > MAN Diesel & Turbo
Combustion Chamber Parts Exhaust Valve – HVOF Coating on Spindle Stem
Company presentation Engine overview Combustion chamber parts Fuel pump parts
FMV Temadag om slid / 2012-11-15 32 < > MAN Diesel & Turbo
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
Company presentation Engine overview Combustion chamber parts Fuel pump parts
FMV Temadag om slid / 2012-11-15 33 < > MAN Diesel & Turbo
Combustion Chamber Parts Exhaust Valve - DuraSpindle
GMAW of
Inconel 718
Austenitic
stainless
valve steel
Rolling process,
10 t load
Age hardening
heat treatment
Company presentation Engine overview Combustion chamber parts Fuel pump parts
FMV Temadag om slid / 2012-11-15 34 < > MAN Diesel & Turbo
Combustion Chamber Parts Exhaust Valve - DuraSpindle
Welding of DuraSpindle
hardfacing (Inconel 718)
Company presentation Engine overview Combustion chamber parts Fuel pump parts
FMV Temadag om slid / 2012-11-15 35 < > MAN Diesel & Turbo
Combustion Chamber Parts Exhaust Valve - DuraSpindle
Rolling depth
1st groove 2nd groove 3rd groove
Rolling of DuraSpindle
hardfacing (Inconel 718)
Company presentation Engine overview Combustion chamber parts Fuel pump parts
FMV Temadag om slid / 2012-11-15 36 < > MAN Diesel & Turbo
Combustion Chamber Parts Exhaust Valve - DuraSpindle
24 hrs
720oC / 8 hrs 620oC / 6 hrs
Hardening of DuraSpindle
hardfacing (Inconel 718)
by 2-stage heat treatment
Company presentation Engine overview Combustion chamber parts Fuel pump parts
FMV Temadag om slid / 2012-11-15 37 < > MAN Diesel & Turbo
Combustion Chamber Parts Exhaust Valve - DuraSpindle
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
Company presentation Engine overview Combustion chamber parts Fuel pump parts
FMV Temadag om slid / 2012-11-15 38 < > MAN Diesel & Turbo
Fuel Pump Parts Plunger and Barrel
Barrel
Plunger
Company presentation Engine overview Combustion chamber parts Fuel pump parts
FMV Temadag om slid / 2012-11-15 39 < > MAN Diesel & Turbo
Fuel Pump Parts Plunger and Barrel
Plasma nitrided
Cr-Al alloyed steel
Nitrided case: min. 0.4 mm
Surface hardness: 900-1100 HV
Company presentation Engine overview Combustion chamber parts Fuel pump parts
FMV Temadag om slid / 2012-11-15 40 < > MAN Diesel & Turbo
Fuel Pump Parts Plunger and Barrel - Scuffing
Scuffing
on plunger
and barrel
Company presentation Engine overview Combustion chamber parts Fuel pump parts
FMV Temadag om slid / 2012-11-15 41 < > MAN Diesel & Turbo
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
Company presentation Engine overview Combustion chamber parts Fuel pump parts
FMV Temadag om slid / 2012-11-15 42 < > MAN Diesel & Turbo
Fuel Pump Parts Bio Fuel Applications
Mouscron, December 2006
17.6 MW Power plant
18V48/60 4-Stroke engine
Refined plant oil
Company presentation Engine overview Combustion chamber parts Fuel pump parts
FMV Temadag om slid / 2012-11-15 43 < > MAN Diesel & Turbo
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)
Company presentation Engine overview Combustion chamber parts Fuel pump parts
FMV Temadag om slid / 2012-11-15 44 < > MAN Diesel & Turbo
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
Company presentation Engine overview Combustion chamber parts Fuel pump parts
FMV Temadag om slid / 2012-11-15 45 < > MAN Diesel & Turbo
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)
Company presentation Engine overview Combustion chamber parts Fuel pump parts
FMV Temadag om slid / 2012-11-15 46 < > MAN Diesel & Turbo
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)
Company presentation Engine overview Combustion chamber parts Fuel pump parts
FMV Temadag om slid / 2012-11-15 47 < > MAN Diesel & Turbo
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)
Company presentation Engine overview Combustion chamber parts Fuel pump parts
FMV Temadag om slid / 2012-11-15 48 < > MAN Diesel & Turbo
Fuel Pump Parts Standard Plunger with Tallow
Fuel pump plunger (nitrided steel) after operation with tallow for 200 hrs (TAN 46, unrefined)
Company presentation Engine overview Combustion chamber parts Fuel pump parts
FMV Temadag om slid / 2012-11-15 49 < > MAN Diesel & Turbo
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
Company presentation Engine overview Combustion chamber parts Fuel pump parts
FMV Temadag om slid / 2012-11-15 50 < > MAN Diesel & Turbo
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.
Company presentation Engine overview Combustion chamber parts Fuel pump parts
FMV Temadag om slid / 2012-11-15 51 < > MAN Diesel & Turbo
Fuel Pump Parts Two-Stroke Engine Operating on Bio Fuel
Larger fuel valves
Introduced
Reinforced camshaft
Introduced
Larger fuel pumps
introduced;
modified materials
Company presentation Engine overview Combustion chamber parts Fuel pump parts
FMV Temadag om slid / 2012-11-15 52 < > MAN Diesel & Turbo
Fuel Pump Parts Two-Stroke Engine Operating on Bio Fuel
Cylinder liner Piston ring
graphite
pearlite
cementite
Company presentation Engine overview Combustion chamber parts Fuel pump parts
FMV Temadag om slid / 2012-11-15 53 < > MAN Diesel & Turbo
Thank you for your attention
FMV Temadag om slid / 2012-11-15 54 < > MAN Diesel & Turbo
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