Wear loaded components in large ship diesel engines

Transcription

1 Wear loaded components in large ship diesel engines Jesper Vejlø Carstensen Copenhagen Material Technology & Research FMV Temadag om slid / < 1 >

2 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 FMV Temadag om slid / < 2 >

3 Two-Stroke Head Office in Copenhagen Employees ( ) : 1,295 Products Engine Components Spare Parts 2-Stroke Engine Design 2-Stroke Engine Components 2-Stroke Engine Spare Parts PrimeServ Academy PrimeServ After Sales Service FMV Temadag om slid / < 3 >

4 MAN Group Corporate Structure MAN SE Business area Commercial Vehicles Power Engineering Division MAN Truck & Bus Employees 11: 34,000 MAN Latin America Employees 11: 2,000 MAN Diesel & Turbo Employees 11: 14,000 RENK (76%) Revenue 11: 9.0 bn Revenue 11: 3.6 bn Revenue 11: 3.6 bn Revenue 11: 0.4 bn The MAN Group in 2011: 16.5 billion revenue - 52,500 employees FMV Temadag om slid / < 4 >

5 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 largebore engines and turbomachinery in use across the world (MAN PrimeServ) FMV Temadag om slid / < 5 >

6 Worldwide No. 1 Supplier of Two-stroke Diesel Engines FMV Temadag om slid / < 6 >

7 Diesel Engine Programme from 450 kw to 87 MW FMV Temadag om slid / < 7 >

8 Licensees Reported Order Books (Two-Stroke) FMV Temadag om slid / < 8 >

9 Market Share (Two-Stroke) 14% 2% LOW SPEED ORDER BOOK ULTIMO JANUARY 2012 MAN B&W Wärtsilä Mitsubishi 84% FMV Temadag om slid / < 9 >

10 Two-stroke Diesel Engine Overview Exhaust receiver Turbocharger Exhaust valve Combustion chamber Piston crown Scavenge ports 12S90ME-C9: Dry mass: 2,070 t Height: 14.5 m Length: 24.2 m Bore diameter: 0.9 m Stroke: 3.3 m Water mist catcher Crosshead Connecting rod Bottom frame Piston rod A-frame Crankshaft FMV Temadag om slid / < 10 >

11 Two-stroke Diesel Engine Combustion Chamber Parts Exhaust valve (spindle) Cylinder cover Fuel injection valve Piston (crown) Cylinder liner FMV Temadag om slid / < 11 >

12 Combustion Chamber Parts Piston Crown, Rings and Skirt Bore cooled piston crown Piston ring pack Piston skirt FMV Temadag om slid / < 12 >

13 Combustion Chamber Parts Piston Rings - Cast Iron surface after polishing surface after etching White phase = cementite Black phase = graphite Chatoyant phase = pearlite Light grey phase = ferrite FMV Temadag om slid / < 13 >

14 Combustion Chamber Parts Piston Rings - Cast Iron pearlite surface after polishing pearlite graphite cementite pearlite surface after etching FMV Temadag om slid / < 14 >

15 Combustion Chamber Parts Piston Rings and Cylinder Liner Cylinder liner Piston ring SO 3 H 2 O Neutralisation Wetting/corrosion graphite pearlite cementite 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 FMV Temadag om slid / < 15 >

16 Combustion Chamber Parts Lube Oil Dosage Minimum oil dosage to maintain hydrodynamic oil film FMV Temadag om slid / < 16 >

17 Combustion Chamber Parts Piston Ring Pack Hard Coat / Soft Coat Ring Package 1st ring Vermicular cast iron base material Chrome-plated bottom face Cermet coating 0.5 mm Alu-coat for running-in 0.1 mm 2nd ring Grey cast iron base material Chrome-plated bottom face Alu-coating 3rd ring Grey cast iron base material Alu-coating Grey cast iron base material Cermet coating 0.3 mm Alu-coat for running-in 0.1 mm 4th ring FMV Temadag om slid / < 17 >

18 Combustion Chamber Parts Plasma Spraying of Piston Ring Pack (W) (Cu) 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. FMV Temadag om slid / < 18 >

19 Combustion Chamber Parts Plasma Sprayed Coatings on Piston Ring Alu-coat Cermet Base material FMV Temadag om slid / < 19 >

20 Combustion Chamber Parts Piston Crown Cross section of piston crown with piston rings (red) Piston ring grooves with hardchrome coating (hardness 900 HV) FMV Temadag om slid / < 20 >

21 Combustion Chamber Parts Piston Crown Ring Groove Wear Worn off layer Demand for increased performance and compact design increased wear FMV Temadag om slid / < 21 >

22 Combustion Chamber Parts Particles in Worn Ring Groove exposed base material hardchrome 50 µm FMV Temadag om slid / < 22 >

23 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 FMV Temadag om slid / < 23 >

24 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 M=Na +, K + D=Ca 2+, Mg 2+ M x D y (Al x+2y Si n-x-2y O 2n ) mh 2 O FMV Temadag om slid / < 24 >

25 S e t t l i n g T a n k 2 ( 6 0 C ) T S e t t l i n g a n k 1 ( 6 0 C ) S e t t l i n g T a n k ( 2 5 C ) Combustion Chamber Parts Fuel Oil System MDO MDO Storage Tank (25 C) HFO Centrifuge(s) (40 C) Service Tank (day) 35 C Service Tank (day) 90 C HFO Supply pump To Gensets HFO Circulating pump If unifuel system 0,0 50,0 100,0 150,0 Viscosity (cst) Sep. efficiency (%) Separation efficiency vs. viscosity Bunker Storage Tank 1 (45 C) Bunker Storage Tank 2 (45 C) Bunker Storage Tank 3 (45 C) Centrifuge(s) ( C) water discharge clean oil discharge solids discharge Temperature (dgr C) Separation efficiency oil feed ldirty Separation efficiency vs. temperature l FMV Temadag om slid / < 25 >

26 Combustion Chamber Parts Ring Groove Wear Mechanisms Rotation of ring results in sliding wear Vertical movement of ring results in impact loads Ring Horizontal movement results in abrasive wear Oil Hard chrome Abrasive FMV Temadag om slid / < 26 >

27 Combustion Chamber Parts Ring Groove Wear Preliminary Solution Hard chrome on piston ring underside Oil Ring Hard chrome Abrasive Hard chrome abrasive wear is minimized FMV Temadag om slid / < 27 >

28 Combustion Chamber Parts Ring Groove Wear Long Term Solution Laser cladded cermet coating with coarse tungsten carbides. Carbide amount: vol% Carbide size: µm Carbide hardness: HV FMV Temadag om slid / < 28 >

29 Combustion Chamber Parts Exhaust Valve Spindle Guide Exhaust valve spindle guide nitrocarburized grey cast iron FMV Temadag om slid / < 29 >

30 Combustion Chamber Parts Exhaust Valve HVOF Coating on Spindle Stem HVOF coating consisting of Cr 3 C 2 in a matrix of NiCr as replacement for hard chrome FMV Temadag om slid / < 30 >

31 Combustion Chamber Parts Exhaust Valve HVOF Coating on Spindle Stem FMV Temadag om slid / < 31 >

32 Combustion Chamber Parts Exhaust Valve Spindle Disc Impact on valve seat area combined with high service temperature and corrosive environment Nimonic 80A Service temperature profile of spindle disc FMV Temadag om slid / < 32 >

33 Combustion Chamber Parts Exhaust Valve - DuraSpindle Austenitic stainless valve steel Rolling process, 10 t load GMAW of Inconel 718 Age hardening heat treatment FMV Temadag om slid / < 33 >

34 Combustion Chamber Parts Exhaust Valve - DuraSpindle Welding of DuraSpindle hardfacing (Inconel 718) FMV Temadag om slid / < 34 >

35 Combustion Chamber Parts Exhaust Valve - DuraSpindle 1st groove 2nd groove 3rd groove Rolling depth Rolling of DuraSpindle hardfacing (Inconel 718) FMV Temadag om slid / < 35 >

36 Combustion Chamber Parts Exhaust Valve - DuraSpindle 720 o C / 8 hrs 620 o C / 6 hrs 24 hrs Hardening of DuraSpindle hardfacing (Inconel 718) by 2-stage heat treatment FMV Temadag om slid / < 36 >

37 Combustion Chamber Parts Exhaust Valve - DuraSpindle Inconel 718 Ni-Cr-W valve steel Potential cost saving is DKK for a K98ME-C exhaust valve Seat hardness: 400 HV Seat hardness: HV S60MC Nimonic spindle, service hrs S60MC DuraSpindle, service hrs FMV Temadag om slid / < 37 >

38 Fuel Pump Parts Plunger and Barrel Barrel Plunger FMV Temadag om slid / < 38 >

39 Fuel Pump Parts Plunger and Barrel Plasma nitrided Cr-Al alloyed steel Nitrided case: min. 0.4 mm Surface hardness: HV FMV Temadag om slid / < 39 >

40 Fuel Pump Parts Plunger and Barrel - Scuffing Scuffing on plunger and barrel FMV Temadag om slid / < 40 >

41 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 FMV Temadag om slid / < 41 >

42 Fuel Pump Parts Bio Fuel Applications Mouscron, December MW Power plant 18V48/60 4-Stroke engine Refined plant oil FMV Temadag om slid / < 42 >

43 Fuel Pump Parts Bio Fuel Applications Wieze, September 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 ( households) FMV Temadag om slid / < 43 >

44 Fuel Pump Parts Bio Fuel Properties Rape seed oil Palm oil Fish oil McDonald frying oil Tallow HFO (ref.) Density at 15 C Heat of combustion Viscosity at 100 C Kg/m MJ/kg 36,89 36,87 36,60 36,85 36,81 39,82 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 FMV Temadag om slid / < 44 >

45 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) FMV Temadag om slid / < 45 >

46 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) FMV Temadag om slid / < 46 >

47 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) FMV Temadag om slid / < 47 >

48 Fuel Pump Parts Standard Plunger with Tallow Fuel pump plunger (nitrided steel) after operation with tallow for 200 hrs (TAN 46, unrefined) FMV Temadag om slid / < 48 >

49 Fuel Pump Parts Bio Fuel Tests on Fuel Pump Test Rig High pressure fuel to fuel valve Drain Fuel pump barrel Fuel pump housing Fuel pump plunger Fuel inlet Piston for puncture valve Puncture valve high pressure Fuel pump top cover Suction valve Lube hole Engine type: 90MC-C Fuel type: Crude palm oil Running hours: 200 hrs 3 tests run with different sets of plunger and barrel: 1. Nitrided steel (ref.) 2. X90CrMoV18 3. HS Steel C% Cr% W% Mo% V% High pressure fuel Low pressure fuel Atmospheric air Drain X90CrMoV HS FMV Temadag om slid / < 49 >

50 Fuel Pump Parts Two-Stroke Engine Operating on Bio Fuel Power plant site from PBB GmbH in Brake, Germany MAN B&W 7L35MC-S engine 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. FMV Temadag om slid / < 50 >

51 Fuel Pump Parts Two-Stroke Engine Operating on Bio Fuel Larger fuel valves Introduced Larger fuel pumps introduced; modified materials Reinforced camshaft Introduced FMV Temadag om slid / < 51 >

52 Fuel Pump Parts Two-Stroke Engine Operating on Bio Fuel Cylinder liner Piston ring graphite pearlite cementite FMV Temadag om slid / < 52 >

53 Thank you for your attention FMV Temadag om slid / < 53 >

54 Disclaimer 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. FMV Temadag om slid / < 54 >