Filtration Handbook
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MussardFiltration Handbook
Uploaded by
MussardFiltration
handbook
Filtration and flushing strategy
2 MAN Energy Solutions
MAN B&W ME-LGIP dual-fuel engines
Future
in the
making
3
Contents
Introduction 04
Purpose of this paper 04
Cleanliness requirement – ISO 4406 versus NAS 1638 06
Filtration ability 07
How to define a filter? 07
Fluid maintenance 08
Filling new oil to tank 09
Cleanliness requirement 10
General flushing conditions 10
Use of flushing equipment 10
Treatment of tank 12
Treatment of pipes and additional installations 12
Topping-up of main tank 15
Temporary filters 16
Safety screen at Multiway Valves 17
How to define contamination level 18
Oil analysis procedure 19
Air amount in oil 21
Recommendations for design of lubricating oil sump tank 21
Guide to contamination control 23
Summary 25
4 MAN Energy Solutions
Filtration handbook
Introduction This will prevent difficulties during has been adopted to keep the number
start-up of the equipment and reduce of scale numbers within a reasonable
The exacting tolerances in today’s the risk of suffering damage to the limit and to ensure that each step is
hydraulic systems require tight control system. meaningful, see Table I.
of the system contamination.
By following the guidelines given in NAS 1638
Experience has shown that impurities this paper, a quicker and more efficient NAS 1638 is an older american
found in the system originate from the flushing process is achieved. standard developed by National
installation and from new oil. Aerospace Standard in 1964 to define
NOTE: The guidelines in this document classes of contamination in aircraft
If not removed, particles will cause are for reference only. For more components and hydraulic fluids.
damage to valves, pumps and detailed information regarding flushing
bearings and, eventually, lead to reference is made to quality The classes refer to the maximum
malfunction of the system and specifications from MAN Energy number of particles in 100mL in
increased wear on the hydraulic Solutions. different size classes.
components. The concept of the code can be seen
Definitions and standards in Table 2. It is based on a fixed
To avoid the above and reduce MAN Energy Solutions specifies the particle size distribution of the
flushing time to a minimum, the whole international ISO 4406 standard to be contaminants over a size range of >5
system must be absolutely clean used when defining the quantity of to >100 microns. From this basic distri-
before filling up with oil and starting up solid particles in the fluid used in a bution, a series of classes covering
the engine. given hydraulic power system. clean or dirty levels has been defined.
The interval between each class is
ISO 4406 double the contamination level, see
Purpose of this paper The scale numbers are allocated Table 2.
according to the number of particles
It is vital that hydraulic system per 100 ml of the fluid sample. A step The standard officially became invalid
installations are carried out in ratio of generally two, as given in 2001 which is why MAN Energy
accordance with the best practices, as between the upper and lower limits for Solutions specifies the international
described in this paper. the number of particles per 100 ml, ISO 4406 standard to be used.
ISO 4406 chart
Number of particles per 100 mI
Range number More than Up to and including
24 8,000,000 16,000,000
23 4,000,000 8,000,000
22 2,000,000 4,000,000
21 1,000,000 2,000,000
20 500,000 1,000,000
19 250,000 500,000
18 130,000 250,000
17 64,000 130,000
16 32,000 64,000
15 16,000 32,000
14 8,000 16,000
13 4,000 8,000
12 2,000 4,000
11 1,000 2,000
10 500 1,000
9 250 500
8 130 250
7 64 130
6 32 64
Table 1: The ISO 4406 standard is a decisive tool defining the quantity of solid particles in the fluid in installations designed by MAN Energy Solutions
5
Class Maximum particles/100 ml in specified size rang (µm)
5-15 15-25 25-50 50-100 >100
0 125 22 4 1 0
0 250 44 8 2 0
1 500 89 16 3 1
2 1,000 178 32 6 1
3 2,000 356 63 11 2
4 4,000 712 126 22 4
5 8,000 1,425 253 45 8
6 16,000 2,850 506 90 16
7 32,000 5,700 1,012 180 32
8 64,000 11,400 2,025 360 64
9 128,000 22,800 4,050 720 128
10 256,000 45,600 8,100 1,440 256
11 512,000 91,200 16,200 2,880 512
12 102,400 182,400 32,400 5,760 1,024
Table 2
6 MAN Energy Solutions
Filtration handbook
Cleanliness requirement – ISO 4406
versus NAS 1638
The recommended standard for
definition of oil cleanliness level is ISO
4406.
If NAS 1638 is used, the number of
particles in a 100 ml sample larger than
6 and/or 14 microns must be within the
range specified by the ISO 4406 code.
Cleanliness level required for ME-System - ISO 4406 Code xx/16/13
ISO 4406 Code 16 → range….min. 32,000………………….max. 64,000 particles > (5)6 microns
NAS 1638 Code 7 → 38,924 particles > 5 microns
NAS 1638 Code 8 → max 77,849 particles > 5 microns
ISO 4406 Code13 range………min. 4,000…………………..max. 8,000 particles > (15)14 microns
NAS 1638 Code 7 → max 6,924 particles > 15 microns
NAS 1638 Code 8 max 13,849 particles > 15 microns
* Number of particles defined for 100 ml sample
** ”max 64.000 particles > (5)6 microns” = (5) microns acc. to ISO 4406(1987-1999), 6 microns acc. to ISO 4406 (1999 →→)
Fig. 1: ISO 4406 vs. NAS 1638 - cleanliness level required for ME/ME-C engines
7
Filtration ability The absolute rating can also be seen as through the filter. Oil samples are taken
a non-realistic definition since no at timed intervals at inlet and outlet of
There are many different ways to make particle larger than the rating can pass the filter. Hereafter the particles in each
filter elements. Although they have through the filter which is not true. sample are measured and counted.
same size, interface and flow capacity The nominal rating is in this respect Based on these results, a beta ratio is
they can be very different in terms of more realistic since it indicates the determined by dividing the number of
their ability to clean the oil from large filters ability to prevent the passage of particles of a particular size in the inlet
and small particles. solid particles greater than the rating with the number of particles of the
together with a percentage of same size in the outlet flow.
Many producers and users tend to efficiency.
mention “Absolute” and “Nominal” For example, if the numbers of 6 micron
filtration rating when specifying and No industry standard for this particles are halved in number from inlet
talking about filters. percentage of efficiency has been to outlet the Beta Ratio is 2/1 = 2 which
made for the nominal rating which also also means the filtration efficiency is
The absolute rating of a filter refers to here makes it difficult to compare 50% and 50% of the 6 micron particles
the diameter of the maximum particle similar filters from different suppliers as are retained in the filter element.
which could pass through the filter. they might define their filters with a
Typically a filtration rating in datasheets different filtration efficiency.
can be mentioned as absolute 3µm, Due to this MAN Energy Solutions How to define a filter?
6um, 10µm, ... prefer to use Beta Ratio when defining
and talking about filtration ability of The following parameters are decisive
However no matter how precise the filters. for a filter definition:
filtration media is made, it is impossible
to ensure that all open areas fulfil these Beta Ratio (β) is a method based on – oil flow
sizes. Particles are also not perfectly laboratory multi-pass tests where a – system pressure
shaped and might be small in one specified contaminate of known sizes is – pressure drop
direction, but large in the other added regularly in measured quantities – operating viscosity
direction. to the oil which is being pumped – filtration ability.
Minimum requirement of cleanliness level – ME hydraulic system ISO 4406 chart
Range Number of particles
number per 100 mI
ISO 4406, Code XX/16/13 More
than
Up to and
including
24 8,000,000 16,000,000
23 4,000,000 8,000,000
22 2,000,000 4,000,000
21 1,000,000 2,000,000
Particle > 14 microns 20 500,000 1,000,000
19 250,000 500,000
Particle > 6 microns 18 130,000 250,000
17 64,000 130,000
Particle > 4 microns 16 32,000 64,000
15 16,000 32,000
This corresponds to a quantity interval of: 14 8,000 16,000
Number of particles > 4 microns, cleanliness code omitted 13 4,000 8,000
12 2,000 4,000
Number of particles > 6 microns from 32,000 to 64,000 in 100 ml sample. 11 1,000 2,000
10 500 1,000
Number of particles > 14 microns from 4,000 to 8,000 in 100 ml sample. 9 250 500
8 130 250
7 64 130
6 32 64
Fig. 2: Filtration requirement for ME/ME-C/ME-B
8 MAN Energy Solutions
Filtration handbook
Fluid maintenance
8,000,000 particles > 6 microns at filter inlet
All fluid stored in sealed containers or
β 6 = ------------------------------------------------------- = 200 → β 6 = 200
delivered from an oil company is
40,000 particles > 6 microns at filter outlet
recommended to be filled through a
filter cartridge with a filtration ability of
β 6 = 200. From ISO 4406 Code 23 to ISO 4406 Code 16 after first pass
Beta ratio: example of filtration ability,
valid for particles > 6 microns
New oil is dirty!
Filter Unit
Filter cartridge ß6 = 200
Filtration ability:
Main tank From ISO 4406 Code 23 to Code 16
Oil delivered from
the Oil Company
ISO 4406 Code 16 ISO 4406 Code 23
(measured after filter) (measured before filter)
Oil delivered from
the Oil Company
Fig. 3: Filtration ability of filter cartridge = β 6 = 200
Example of contaminants amount to be removed
Given that we assume that the particles are cubic sized.
For example 6 micron => ( 0.0006 x 0.0006 x 0.0006 ) x particle amount in specific ISO 4406 code (100 mL) x 10,000 = cm 3 /1,000 litres oil tank
The table below can be used to define the filter-cartridge dirt and contaminants capacity
ISO 4406 Code xx → Code xx Max. contaminants amount to be removed in cm3/1000 litres oil tank
Code 23 to Code 16 for particles > 6 microns (new oil at delivery date) 17.1
From Code 19 to Code 16 for particles > 6 microns 1.0
From Code 16 to Code 13 for particles > 14 microns 6.6
Table 3
9
Filling new oil to tank Example: How to choose the correct removed, i.e. 48 m3 x 1.0 cm3/m3 =
filter cartridge size. 48 cm3 (from look-up in table 4:
Data sheets of filter elements often filtertype 250 and 6 µm).
mention retention capacity in gram at a Steps to follow:
certain pressure drop since the test – Oil amount of 48,000 litres must be Conclusion of example:
method is to weight the filter elements moved to hydraulic tank. – Filter element: 0250 DN 6 BN/HC/-V
after testing.
– Pump equipment (flow): 200 l/min. → – Filtration time: 48,000/200 = 240 min
In order to use this when sizing a filter 12 m3/h → 4 hours.
element we might assume that 1 gram
= 1 cm3. – To be cleaned from ISO 4406 Code – Final cleanliness level: ISO 4406
19 to ISO 4406 Code 16 for particles Code 16 (for particles > 6 microns).
Steel and rust particles are heavier, but > 6 microns = 1.0 cm3/m3 (Table 3).
normally a minority compared with dust
and
cloth particles which are lighter.
– Contaminants > 6 microns to be
Fig. 4: Data
for filter
element
,
,
,
,
,
,
,
,
,
Table 4
¡
¡
¡ ¢£¤
¡
¡ ¢£¤
¡ ¢£¤
Table 5
10 MAN Energy Solutions
Filtration handbook
Cleanliness requirement General flushing conditions Use of flushing equipment
The cleanliness level for the lubricating When preheating is available, MAN For filling and topping up, it is
oil used for flushing the main engine Energy Solutions recommends recommended to use a filter cartridge
must comply with ISO 4406 Code preheating the oil to a temperature of with a filtration ability of β 6 = 200.
xx/19/15. 60-65 degrees Celsius.
For flushing, a filtration ability of
The cleanliness level for the lubricating To ensure a sufficiently turbulent flow in minimum β10 = 75 is needed, however,
oil used for flow cleaning the ME the system, the oil flow velocity must, as MAN Energy Solutions recommends a
system must comply with ISO 4406 a minimum, reach a Reynolds number filter with a minimum filtration ability of
Code xx/16/13. higher than 3,000, see also Fig. 5. β 6 = 75.
However if using a ME-filter with a Formula for calculating the Reynolds For additional flushing filters, so-called
filtration ability β 6=min.8 which often is number: “off-line” filters, a minimum
installed in the redundancy part of the filtration ability of β 6 = 75 is
ME filter arrangement and known as (V×D) recommended, and a minimum
Re = ─── 1,000
SFF (Super Fine Filter), it is possible to η filtration ability of β10 = 75 is needed.
clean the oil from ISO code xx/19/15 to
ISO code xx/16/13 in a single pass Re – Reynolds number Use of ME-filter for flushing is
through the filter. η – kinematic viscosity (cSt) recommended. Backflushing oil must
V – flow velocity (m/s) be returned to a separate backflushing
This enable the opportunity to begin D – inner pipe diameter (mm) tank and then back to the main tank via
flushing of the ME-system when the a β 6 = 200 filter cartridge.
cleanliness level measured before the Example:
ME-filter is in minimum ISO 4406 Code Reynolds number 3,000 MAN Energy Solutions recommends
xx/19/15. Inner pipe diameter 300 mm (0.3 m) use of a purifier during flushing. A
Oil viscosity 112 cSt portable vibrator or hammer can be
When the oil cleanliness level in the used on the outside of the lube oil
tank is according to the above, flushing Calculation of minimum flow velocity: pipes to loosen impurities in the piping
of the main engine and ME-system can system.
Re
be performed in parallel. ( ── )✕ η
1,000
V=──── =1.12m/s It is also recommended to circulate oil
D
The oil must circulate for more time through the system at maximum pump
during flushing since entrapped Calculation of minimum pump flow: capacity, but not higher than the
particles in the system will be loosened maximum capacity of the filters.
(π)
and affect the cleanliness. Q=D2 ── ✕1.12✕60,000=4,750 L/min
4
The nomograms shown in Fig. 5 can be
We recommend to follow the flushing used for estimation of the flow velocity
procedures from MAN Energy required to reach a Reynolds number
Solutions. higher than 3,000.
11
Flow
(l/min)
Flow needed for Re = 3,000 at 112 cSt
12,000
10,000
8,000
Min. flow via ”Ru” inlet – 6,185 l/min
6,000
4,000
2,000
0
150 250 350 450 550 650
Pipe diameter (mm)
Fig. 5: Flow/flow velocity nomogram
Flow velocity
(m/s)
Flow velocity needed for Re = 3,000 at 112 cSt
7,000
6,000
5,000
4,000
3,000
2,000
Min. flow velocity via ”Ru” inlet – 0.86 m/s
1,000
0
50 150 250 350 450 550 650
Pipe diameter (mm)
Fig. 6: Flow/flow velocity nomogram
12 MAN Energy Solutions
Filtration handbook
Treatment of tank Cleaning of the oil tank agent. If rust is found, the inner surface
New or repaired components are often must be treated with de-rust agent.
Each single surface of the tank, the carriers of contamination. Before Use compressed air to remove small
horizontal and vertical, must be final assembly, this built-in particles from the surface. Degrease all
cleaned as described below: contamination must be removed from pipes using grease-dissolving liquid.
the blocks, pipes, oil tank and any other Pipes that have been treated with acid
– any slag (and other impurities) after components prepared for use in the are to be neutralised or washed in a
welding must be removed system. combination of cleaning/neutralising
mechanically agents.
– clean all visible impurities Treatment of pipes and additional Cleaned areas must be protected with
installations an anti-rust agent immediately after
– treat scale on the surface with a being cleaned, so as to provide
de-scaling agent Hydraulic pipes should only be welded protection until the system is filled up.
if absolutely necessary. If so, each The agent must be of a type that can
– if rust is found, treat the surface with welding point must be placed so that be mixed with lubricating oil.
de-rust agent mechanical removal of any welding slag
is possible. When a pipe is treated with an internal
– use a vacuum cleaner to remove protection agent, open connections
small particles from the surface and All pipe dimensions larger than ø25 mm must be blanked off (remember to
corners (externally) should be fitted with flanges remove all temporary gaskets and
if possible. The flanges and pipes must plugs, before assembly).
– wash the surface with always follow the requirements of the
grease-dissolving liquid. class.
Cleaned areas must be protected with All cut surfaces must be ground, and
anti-rust agent immediately after they the inner surface must be smooth. Any
have been cleaned, so as to provide slag (and other impurities) must be
protection until the system is filled up. removed mechanically. Clean all visible
The agent must be of a type that can impurities. Scale on the inner surface
be mixed with lubricating oil. must be treated with a de-scaling
Contermination found in ‘clean’ oil tank
Fig. 7: Empty hydraulic oil tank
13
MAN Energy Solutions advice to use
a filter for filling of the oil tank (on
the test bed, at shipyard, on board)
Use a filter unit for filling and
simultaneous cleaning (filtration during
filling):
– fi
lter cartridge with a beta rating of
β 6 = 200
For flushing of the system, please
follow, MAN Energy Solutions Quality
Specifications.
Filter position as close as possible to storage/main tank
Main tank Filling unit
Filter cartridge filtration ability: ß6 = 200:
From ISO 4406 Code 23 to 16 after one pass.
Sample point assembly (minimess):
Always vertical position and connected to upper part of pipe
Fig. 8: Hydraulic oil tank filled
14 MAN Energy Solutions
Filtration handbook
Flushing procedure for ME The time required to clean the ME during quay trial and sea trial, and for
installations when using the system to ISO 4406 Code xx/16/13 the following 14 days after that.
conventional ME-filter (redunancy cleanliness level, can be greatly
filter). reduced by fitting a filter cartridge with After this period, the ME lube oil flow
a filtration ability of minimum β 6 = 8 to can be switched back to run through
For newer installations where an the ME redundancy filter and then the main filter (Pos. 106) for normal
alternative ME-filter solution like directing the main lube oil flow through engine service running.
Boll & Kirch 6.49 or similar is also this filter.
used. Here the main filter is β 6 = This solution is time saving for the crew
min.8 and the mentioned oil The described configuration is and has no negative effects on the
filtration can be done directly recommended to be applied on all service life of the redundancy filter.
without changes at the filter. new installations on the test bed,
Filter outlet after first pass => ISO 4406 Code xx/16/13
POS. 103
POS. 107
-POS. 106
POS. 105
Use of filter cartridge with
filtration ability of minimum
β6=8 in redundacy filter
POS. 108
POS. 103
POS. 101
Lube oil inlet 1 Lube oil inlet - 2.2 bar
Filter inlet - ISO 4406 Code xx/19/15
Backflushing oil to purifier Backflushing oil to purifier
Air inlet - 7 bar
Fig. 12: Flushing through ME redundancy filter fitted with a high-filtration ability filter cartridge
15
Topping-up of main tank Unlimited topping-up of the main tank system increase when using a new oil
without the above filter will result in and when partly refilling the system
Valid on test bed and for installations in increased wear of valves, pumps and with new oil.
service bearings and, eventually, will lead to
All fluid delivered from an oil company malfunction of the systems. Therefore, you will see that the number
must be filled through a filter cartridge of particles caught in the filter system
with filtration ability of β 6 (beta) = 200. For installations without the necessary increases in the period after, no matter
filling equipment, the rules described in if you added filtered new oil or not.
As mentioned, this is not only important the following must be observed.
to prevent difficulties during start-up, The cleaning additives in a new oil
but also when topping up the main tank The cleaning efficiency of the system simply just works better than in an old
for installations in service. and the release of particles from the oil.
Number of particles
(in 100 ml sample) Topping of tank MC
1,000,000 No. of particles acc. to ISO 4406
(max in 100 ml sample)
900,000
No. of particles > 6 microns at start
800,000
point (max in 100 ml sample)
700,000
No. of particles > 6 microns after
600,000 topping (max in 100 ml sample)
500,000 No. of particles allowed ISO 4406
Code 17, (max in 100 ml sample)
400,000
300,000
200,000
100,000
0
0 0.2 0.4 0.6 0.8 1 1.2 1.4 1.6 1.8 2 2.2 2.4 2.6 2.8 3 3.2
Oil added (in % of total oil amount)
Fig. 13: Installations in service, max. 3% of tank capacity per day
Number of particles
(in 100 ml sample) Topping of tank ME
250,000
No. of particles acc. to ISO 4406
240,000
230,000 (max in 100 ml sample)
220,000
210,000
200,000 No. of particles > 6 microns at start
190,000 point (max in 100 ml sample)
180,000
170,000
160,000 No. of particles > 6 microns after
150,000 topping (max in 100 ml sample)
140,000
130,000
120,000 No. of particles allowed ISO 4406
110,000 Code 17, (max in 100 ml sample)
100,000
90,000
80,000
70,000
60,000
50,000
40,000
30,000
20,000
10,000
0
0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1 1.1
Oil added (in % of total oil amount)
Fig. 14: Installations in service, max. 1% of tank capacity per day
16 MAN Energy Solutions
Filtration handbook
Temporary filters
FIVA
A temporary filter can be used main valve
between the FIVA main valve and the
FIVA pilot valve, and also the HPS
pump and the pilot valve for pump
control. However, the filters must be
removed after sea trial.
The reason is to install an extra
protection of all control valves which
demands high oil cleanliness since the
first hours of engine running will
release particles that the flushing did
not catch as illustrated at fig. 16.
Oil cleanliness
ISO 4406 xx/19/15
Particles released at
the start of shop test
ISO 4406 xx/16/13
Flushing Shop test/seatrial Hours
FIVA
Start of shop test
Mounting of filter
End of shop test/seatrial
pilot valve Temporary filter to be removed after sea
trial and returned to the engine builder
Fig. 16:
Fig. 15: FIVA unit with temporary filter
In 2010, the same type of Hydac
sandwich filter was installed for testing
in service for two months on ELFI
B3-45. The test result was positive with
no performance change recorded.
Pilot spool feedback [mA]
→
10
12
Hydac sandwich filter on ELFI-B3-45
4 Main spool
feedback [mm]
-4
0 0,06 0,12 0,18 0,24 0,30
Seconds →
Fig. 17: The Hydac sandwich filter has been tested successfully without any performance change on
ELFI-B3-45 at the MAN Energy Solutions research centre in Copenhagen
17
Safety screen at Multiway Valves
I 2019 we introduced Multiway Valves
like FIVA, ELFI, ELVA and PEVA with a
safety screen in the oil line for the
controlling proportional valve.
The safety screen is a small filter
strainer with a mesh size of 100 µm
which intend to minimize the risk of
larger particle to enter and disturb the
function the controlling proportional
valve.
After a service test of almost 6,000
running hours the safety screen was
inspected and large particles were
found which could have resulted in a
malfunction of the valve.
All Multiway Valves equipped with a
safety screen will need to have the filter
strainer inspected and cleaned every
6,000 running hours or approximately
once a year.
Bottom piece
Fig. 18: FIVA with new bottom piece for permanent filter
Filter
Nut
Plug
Bottom piece
Fig. 19: New bottom piece showing filter placement and assembly order. Fig. 20: Filter with large particles
18 MAN Energy Solutions
Filtration handbook
How to define contamination level
Cleanliness of hydraulic oil is normally Vacuum
examined by the laser method. pump
However, this is not a suitable method
for system oil, as system oil is black
containing soot, small water-droplets,
air-bubbles etc. which the laser
method (ISO 11500) counts as
particles, but which do not harm the
engine components. The microscope
method removes the soot etc. and do
merely look at actual particles. MAN Solvent
Energy Solutions therefore Sample Membran
recommends to use the microscope bottles containers
method (ISO 4407).
The results show, that for used oil
samples the microscope method
measures 4-6 cleanliness classes
below the laser method.
Fig.21: How to collect contaminants for examination
MAN Energy Solutions recommend on
regular basis, when lube oil samples
are send ashore for analyse, that a
particle counting are also performed
on the ME Hydraulic System oil
according ISO 4407 which is particle
counting by microscope method.
A filter diaphragm with all
contaminants from a 100 ml sample
must be prepared. The recommended
sample point position is diagram Pos.
340 or Pos. 425. In the P2 line of the
ME system. Minimess sample points
at the ME-filter inlet and outlet are
also recommendable.
Sample bottles should be clean to
reduce the interference of
contaminants from the bottles. Use
the bottles cleaned and validated in
accordance with ISO 3722 and BS Fig. 22: Magnifier and comparator book
5540.
Using a vacuum pump, a
representative sample of hydraulic
fluid, usually 100 ml, is drawn from the
70ºC preheated system through a 47 suitable solvent filtered through a 1.2 same magnification. Use of a
mm diameter laboratory membrane micron filter mesh, and the membrane comparator book for this analysis is
filter disc with a filter mesh size of 1.2 filter disc is transferred to a suitable recommended.
microns. protected container.
All contaminants larger than 1.2 Analyse the membrane filter disc
micron are collected on the surface of under microscope and compare a
the filter disc. Residual sample fluid is view on a prepared filter diaphragm
washed from the filter disc using a with the ”comparator” picture with the
19
Oil analysis procedure
1. Heat oil samples in an oven to around 70°C. 2. Prepare the test equipment 3. Take one 1,2 micron filter disc by forceps and
This will usual take one hour. The heating of the place it at the top of the funnel
oil samples are important in order to be able to
draw the oil though the filter discs
4. Clamp the measuring glass on the top 5. Take a well heated oil sample and shake it 6. Start the vacuum pump and the oil will be
thoroughly for half a minute. Remove the screw drawn through the filter disc to the bottle below.
cap and fil the measuring glass to the 100 mL
mark. Stop the vacuum pump when the oil is through.
20 MAN Energy Solutions
Filtration handbook
7. Spray solvent / benzine onto the sides of the 8. Start the vacuum pump and the solvent / 9. Place by forceps the filter disc into the suitable
measuring glass and wait a minute so the benzine will be drawn through the filter disc. container.
solvent can dissolve the black soot particles Stop the vaccum pump afterwards and remove
the clamp together with the measuring glass. Now the filter disc is ready to examinate under
microscope.
Normally the filter disc would visually
look fairly clean since our eyes cannot
see particles smaller than 40 µm.
However sometimes it is possible to
determine if the cleanliness is not okay
or not before analyse under
microscope.
Fig. 23: Example of too dirty filter disc
21
Air amount in oil Recommendations for design of – T o de-aerate and degas the
lubricating oil sump tank lubricating oil
Another important factor together with – To act as a storage tank of the total
keeping the oil clean is to ensure a low A way to keep the air content low is to volume of lubricating oil
amount of air in the oil. ensure that the oil level in the tank – To contain the necessary oil volume
never is under minimum level. in order to avoid a too high
A high content of air in the oil will circulating rate
decrease the efficiency of the hydraulic Because if the oil circulating rate is too – To avoid that air be sucked by the
system as well as increase cavitation high the oil will not have sufficient time lubricating oil pumps
and wear at the hydraulic components. for deaeration.
The tank is located under the
It is the responsibility of the ship 1. Considerations about Design of crankcase oil pan, in order to facilitate
designer to ensure that the amount of Lubricating Oil Sump Tank the oil flow from the crankcase outlets.
air in the oil (Xair) put into the engine by The lubricating oil sump tank for the It has to be designed with a
the main lube oil pumps, does not two-stroke marine diesel engines has symmetrical cross section to avoid
exceed a maximum 1.5%. several functions which are shortly bedplate distortions.
listed here, as a basis for the
This is to be confirmed on sea trial with recommendations that will be given Usually, there is a cofferdam under the
the engine running in 100% load. An oil later on: lubricating oil sump tank.
sample is to be made from the main
low pressure supply line on the main – T
o settle the solid particles that will If the ship is not equipped with a
engine downstream after the be separated by the centrifuges cofferdam below the lubricating oil
de-aerating nozzle shown in the main
lubricating oil system diagram.
A
Such an oil sample must be made by
using a bottle similar to the ones shown
in fig. 24.
First the initial oil volume must be
noted, see fig. 24 (A). The oil sample
volume is to be evaluated after 24h in
order to assume no air content in the
final oil volume, see fig. 24 (B).
A
V init
e
Cofferdam
V final
e
Cofferdam valve
Fig. 24: Design proposal Fig. 25: A: Cofferdam below oil tank. B: No cofferdam below oil tank and valve in oil outlet
22 MAN Energy Solutions
Filtration handbook
bottom tank, the lubricating oil outlet In other cases, especially for engines to 10% more than the initial oil filling
from the engine can be equipped with with a large numbers of cylinders the volume with pumps stopped.
valves in the outlet, if required by the tank size might be too big using the
classification society. This can also be length extension of the engine as tank When taking the above into
arranged with emergency suction from boundaries. For those engines the lub. consideration, the normally acceptable
the engine oil pan. oil bottom tank can be designed as range of tank volume will be between:
below fig. 26.
2. Lubricating Oil Volume and Maximum tank volume:
Circulating Rate Example: 18.7×1.10=20.6 m³
The lubricating oil sump tank has to be Pump capacity: 280 m³/h
dimensioned in accordance with the No. of oil circulations per hour: 15 l/h Minimum tank volume:
main lubricating oil pump capacity and 15.6×1.05=16.4 m³
the recommended circulating rate, That means that the total oil volume
which should be between 15 and 18 should be between: Therefore, the tank volume is to be
times per hour. increased corresponding to the
– R ecommended maximum oil volume volume of the oil from the system
In some cases, when space is limited, it (in circulation): 280/15=18.7 m³ outside the engine – if such a system
might be necessary to reduce the tank – Recommended minimum oil volume is present.
size to a minimum. However, it will not (in circulation): 280/18=15.6 m³
– under any circumstances – be
advisable to increase the circulating It is good practice to design the tank
rate to more than 20 times per hour. volume with a capacity of approx. 5%
Cyl. 11
Cyl. 10
Cyl. 9
Cyl. 8
Cyl. 7
Cyl. 6
Cyl. 5
Cyl. 4
Cyl. 3
Cyl. 2
Cyl. 1
Elevation view
Not part of the lub. oil bottom tank
Top view
Fig. 26: Design proposal
23
Guide to contamination control
When the engine is delivered in several
parts, flushing of the engine at the
shipyard is needed.
Dismantling of ME parts before sending
to yard
If the ME-system is dismantled before
being sent to the shipyard, flushing of
the system must be performed on
board.
Guide to System Contamination Control
Engine builder Sub-supplier
Cleaning of main tank
Filling of the oil tank + oil cleaning
(use of the filling filter recomended)
Cleaning of pipes and new installations
(use of the filling filter recomended)
Engine flushing
(use of the filling filter recomended)
ISO 4406 Code xx/19/15
ISO 4406 Code xx/16/13
ME-system, flow cleaning
(use of ME filter necessary)
Shop test
Fig. 27: Flushing at the shipyard
24 MAN Energy Solutions
Filtration handbook
Even when delivered finish-assembled,
flushing of the main engine must be
performed at the shipyard. The ME-sys-
tem can be omitted if the main engine
is delivered without opening of the
ME-system.
Guide to System Contamination Control
Shipyard
Filling of shipyard installations
(use of additional filter recommended)
Engine delivery
in several parts
Engine delivery complete
perform engine flushing
Engine flushing
ME system flushing avoided
(use of additonal filter
recommended)
ME parts delivery in one part ME system opened for delivery
ME system cleaning avoided ME system flushing to be performed
Quay trial
Fig. 28: Flushing of shipyard installations only
25
Summary
The starting point for every filtration
and flushing strategy is that all new oil
is dirty. The proper cleaning and
flushing of hydraulic systems is
therefore vital to ensure reliable and
longterm operation without unexpected
downtime of the system for
maintenance and repair.
MAN Energy Solutions recommends
following the standards and guidelines
described in this paper, so as to
achieve the best possible system
condition on low speed MAN B&W
two-stroke diesel engines.
This includes application of the ISO
4406 standard and use of the proper
filter cartridges for filtration and the
proper filters for flushing. Furthermore,
it is important to monitor the
cleanliness level of the oil by means of
onsite fluid analyses, in order to be able
to control the level of contamination.
MAN Energy Solutions
2450 Copenhagen SV, Denmark
P +45 33 85 11 00
F +45 33 85 10 30
[email protected]
www.man-es.com
All data provided in this document is non-binding.
This data serves informational purposes only and
is 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.
Copyright © MAN Energy Solutions.
5510-0102-06ppr May 2023. Printed in Denmark
