ETEESE17-1683

ETEESE17-1683
To: Mitsubishi Heavy Industries Enqine System Asia Pte. Ltd.
Investigation repo同about Lube oil main

’
filter s difference pressure alarm
S 16U-PTK generator set of Eastern Refinery Limited at Bangladesh
Approved Check Author
A.Suルィ
M.SUGIYAMA
1<,fatva�
K.SAWAZAKI H.TSUJISHITA
March 5th, 2018
MITSUBISHI HEAVY INDUSTRIES ENGINE & TURBOCHARGER, LTD.
Engine Engineering Section, Engine Department, Engine & Energy Division
。 2018 MITSUBISHI HEAVY INDUSTRIES ENGINE & TURBOCHARGER, LTD. All Rights Reserved.
人 MITSUBIS闘HEAVY削DUST剛ES
ENGINE & TURBOCHARGER, LTD.
Background
About Engine
 Customer: Eastern Refinery Limited, Bangladesh
 Engine model: S16U-PTK
 Serial No.: 10155
 Rated output and speed: 2,000 kW / 750 min-1
 Manufacturing Date: February 2015
 Commissioning Date: January 2016
 Running hour: 15,834 hrs
 Total generator load: 20,430,879 kWh
 Average load: 1,292 kW (64.6%)
About Maintenance work

 Maintenance Menu: Rank E Maintenance (Top overhaul)
 Work period: from January 22nd, 2018 to February 12th, 2018
 Contractor: Rahimafrooz Energy Services Ltd
© 2018 MITSUBISHI HEAVY INDUSTRIES ENGINE & TURBOCHARGER, LTD. All Rights Reserved. 2
Failure history that MHI group received
November 15th, 2016: L.O. FILTER DIFF. PRESS HIGH alarm was activated within
1,000 hrs (accurate hour is 922 hrs according to the log) from maintenance. lube oil
main filter elements were changed. This is first information about this failure.
(received at November 16th)
February 15th, 2017: L.O. FILTER DIFF. PRESS HIGH alarm was activated at 615
hrs (accurate hour is 586 hrs according to the log) from maintenance. Lube oil and
lube oil main filter elements were changed. (received at February 16th)
April 13th to 26th, 2017: The oil filter assy was transferred from the common bed to
separately bracket. At the same time, the differential pressure transmitter was
installed in the lube oil main filter.
May 8th, 2017: L.O. FILTER DIFF. PRESS HIGH alarm was activated at 297 hrs
from maintenance. (received at May 8th)
May 23rd, 2017: L.O. FILTER DIFF. PRESS HIGH alarm was activated at 333 hrs
from the last maintenance. (received at May 23rd)
June 14th, 2017: Breather pipe was checked and lube oil main filter element and
nozzle tip are replaced. (operation hour is 10,926 according to the log) (received at
June 22nd)
Engine condition before maintenance
Exhaust gas condition at 1,250 kW is black L.O. FILTER DIFF. PRESS HIGH alarm
was activated.
Blow-by combustion gas at 1,250kW is a Lube oil filter differential press was over
little too much than around 500 kPa
Nozzle tip condition
Much carbon was adhered on the all nozzle tips.
No.1: Much carbon No.8: Much carbon No.13: Much carbon No.16: Much carbon
was adhered. was adhered. was adhered. was adhered.
Five nozzle tips had bad spray pattern.
No.4: Not abnormal No.6: Splay pattern is No.8: One nozzle hole No.13: After dribble
bad since nozzle holes is completely clogged.
are partly clogged.
Inspection result of Fuel spray
Cyl Injection Spray condition Cyl Injection Spray condition

No. start press No. start press
[MPa] [MPa]
1 36 Not abnormal 9 38 Partly clogged
2 37 Not abnormal 10 35 Not abnormal
4 36 Not abnormal 12 36 After dribble
5 35 Not abnormal 13 39 After dribble
6 32 Partly clogged 14 28 Not abnormal
8 34 Clogged 16 35 Not abnormal
Three nozzle tips are clogged.

Two nozzle tips have after dribble.
Injection start pressure of six nozzle tips is larger or smaller than the standard value
34.8 to 35.3 MPa that written in the service manual.
Combustion chamber condition
No.5
Carbon adhered condition in the Carbon adhered condition in the cylinder

combustion chamber. head.
No.5
Cylinder liner was locally worn by the carbon Much carbon was adhered on top and in
adhered on the piston ring grooves of the piston.
Surface condition of Cylinder liner (after cleaning)
No.5 No.13
Rear side of upper part was widely worn. Rear side of upper part was widely worn.
No.6 No.16
Rear side of upper part was widely worn. Front side of middle part was worn.
Result of Cylinder liner visual inspection
Cyl Cyl
Surface condition Surface condition
No. No.
1 Not abnormal 9 Not abnormal
2 Not abnormal 10 Scratch
3 Not abnormal 11 Not abnormal
4 Not abnormal 12 A little scratch
5 Much scratch 13 Mirror surface
6 A little scratch 14 Not abnormal
7 Scratch 15 Scratch
8 Not abnormal 16 Scratch
Eight cylinder liners out of sixteen were scratched and worn by adhered carbon.
The surface of one of them has mirrored since wear progressed.
Engine condition after maintenance
Exhaust gas condition at 1,020 kW. Black All alarms were not activated.
smoke decreased than before maintenance.
Blow-by combustion gas at 1,512 kW is Lube oil filter diff press was around 0 kPa.
decreased than before maintenance.
Findings during inspection & maintenance
No. Item Findings
• Much carbon was adhered on the all nozzle tips.

1 Nozzle tip
• Spray condition of five nozzle tips was bad.
2 Combustion chamber • Much carbon was adhered in all cylinders.
• Much carbon was adhered on top and in ring

3 Piston
grooves.
• Eight cylinder liners were scratched and worn by

4 Cylinder liner
adhered carbon.
• After maintenance black smoke decreased than

5 Exhaust gas
before maintenance.
• After maintenance it decreased than before

6 Blow-by combustion gas
maintenance.
Failure mechanism of lube oil filter diff press
Based on the findings, the failure mechanism of lube oil main filter differential
pressure alarm issue is shown as below.
1. Much soot was made due to bad combustion and much carbon was adhered in
the combustion chamber.
2. These adhered carbon on top and in ring grooves of the piston made the
cylinder liner surface wear locally earlier than usual.
3. As cylinder liner surface worn, more blow-by combustion gas including the
much soot blew through the crankcase than normal during the operation. Then,
the soot was mixed into the lube oil. By the mixture of the soot with lube oil, the
sludge in the lube oil increased.
4. During the engine operation, the sludge in the lube oil was adhered to the lube
oil main filter element, which caused the differential pressure higher and the
alarm activated in the shorter interval than normal.
Fault tree analysis of Bad combustion
This page shows the fault tree analysis regarding to combustion becoming worse
than normal.
Top Event Cause Check Result Judge
Fuel property
Bad combustion Fuel analysis Did not carry out unknown
problem
Injection nozzle Spray condition

Spray test possible
problem was bad
Injection timing is Measure injection All cylinder is 14

n/a
delayed timing degrees
Turbocharger Check rotor of

Rotated smoothly n/a
breakage turbocharger
Air cleaner
Check for clogging No clogging n/a
clogging
Exhaust muffler
Check for clogging No clogging n/a
clogging
Operation of under Long time operation with

Check the log a load of 30% or less
possible
low load
Trend graph of Crankcase pressure
2500 1.6
Used hour of Oil & Element [hr]

1.4
Crankcase press [kPa]

2000 1.2
1
1500 0.8
0.6
1000 0.4
0.2
500 0
-0.2
0 -0.4
0 3000 6000 9000 12000 15000
Engine operation hour [hr]
Lube oil Filter element Alarm Crankcase press
Crankcase pressure increased from 6,000 hrs of engine operation hour. Pressure
increasing shows that cylinder liner surface was worn and combustion gas blown
through between cylinder liner and piston to crankcase was increased.
It coincides with the time when the alarm was activated within 1,000 hrs.
Exchange history of Nozzle tip
2500 1.6
Used hour of Oil & Element [hr]

1.4
Crankcase press [kPa]

2000 6,336 hrs 4,590 hrs 4,908 hrs 1.2
1
1500 0.8
0.6
1000 0.4
0.2
500 0
-0.2
0 -0.4
0 3000 6000 9000 12000 15000
Engine operation hour [hr]
Lube oil Filter element Alarm Crankcase press
MHIET presume that nozzle tips were used 1.5 to 2 times longer 3,000 hrs which
our recommended replacement interval.
6,336 hrs of the first replacement of nozzle tips is more than double of 3,000 hrs.
Immediately before that the crankcase pressure has increased sharply.
Analysis result of Lube oil (1/2)
1) Kinetic viscosity @ 100℃ [mm2/s] 2) TBN [mg KOH/g]

20 14
Upper limit: 19.0 (New oil +30%)
19 13
18 12
17 11
16 10
15
9
14
13 8
12 7
11 6
10 5
Lower limit: 10.0 Lower limit: 5.0 (New oil – 50%)
9 4
0 500 1000 1500 0 500 1000 1500
Engine operating hour from Lube oil Engine operating hour from Lube oil
change [hr] change [hr]
ERL 2017 ERL 2016 MHI 2017 MHI 2016 ERL 2017 ERL 2016 MHI 2017 MHI 2016
Kinetic viscosity used for 1,499 hrs analyzed at November 29, 2017 is low. It is
possible that fuel dilution has occurred.
TBN of fresh lube oil in 2017 decreased from 11 to 10 compared to 2016.
Analysis result of Lube oil (2/2)
3) Pentane insoluble [wt%] 4) Condensation Pentane insoluble [wt%]

0.6 0.6
Upper limit: 0.5 Upper limit: 0.5
0.5 0.5
0.4 0.4
0.3 0.3
0.2 0.2
0.1 0.1
0 0
0 500 1000 1500 0 500 1000 1500
Engine operating hour from Lube oil Engine operating hour from Lube oil
change [hr] change [hr]
ERL 2017 ERL 2016 MHI 2017 MHI 2016 ERL 2017 ERL 2016 MHI 2017 MHI 2016
Pentane insoluble matter has increased compare to 2016. However the value is
below the upper limit 0.5.
MHI did not received analysis result of condensation pentane insoluble.
Trend graph of Real power
2000 100%
1800 90%
Real load
1600 80%
Load of 30% or less
Real power [kW]
1400 70%
Load factor
1200 60%
1000 50%
800 40%
600 30%
400 20%
200 10%
0 0%
29-Nov-2017
30-Nov-2017
10-Dec-2017
11-Dec-2017
1-Dec-2017
2-Dec-2017
3-Dec-2017
4-Dec-2017
5-Dec-2017
6-Dec-2017
7-Dec-2017
8-Dec-2017
9-Dec-2017
From the log MHIET found that the engine was sometimes operated under low load. The
graph is shown that the engine was operated for a long time with a load of 30% or less.
The operation manual is stated that operation with load of 30% or less should be less
than 10 minutes. Long time operation of under low load possibly occurs some problems.
Conclusion
According to findings of Rank-E maintenance (top overhaul), the cause of L.O.

FILTER DIFF. PRESS HIGH alarm issue is shown as bellow.
 Blow-by combustion gas and soot were much than usual and they increased the sludge in
lube oil.
 The differential pressure increased earlier than usual due to the much sludge adhered the
filter element.
It is assumed that the blow-by gas increased from 6,000 hrs of engine operation
hour. The reason is shown as bellow.
 Crankcase pressure increased from 6,000 hrs.
 L.O. FILTER DIFF. PRESS HIGH alarm issue has occurred from 6,000 hrs.
It is assumed that the cause of blow-by gas increasing is shown as bellow.
 Much soot was made and adhered in the combustion chamber due to (a) using the nozzle
tip1.5 to 2 times longer than the recommended replacement interval and (b) long time
operation with load of 30% or less.
 These adhered carbon on top and in ring grooves of the piston made the cylinder liner
surface wear locally earlier than usual.
Kinetic viscosity of used lube oil for 1,499 hrs analyzed at November 29, 2017 is
low. It is possible that fuel dilution has occurred.
Recommendation about filter alarm issue
The maintenance should be carried out according to the MHIET recommended

maintenance menu to keep the engine in proper condition. Please see the attached
document for details.
In particular, the nozzle tip that is possible root cause of L.O. FILTER DIFF. PRESS
HIGH alarm issue should be replaced every 3,000 hrs.
MHIET recommend to replace the cylinder liner as soon as possible.

Black smoke is decreased by Rank-E maintenance. However it is possible that L.O.
FILTER DIFF. PRESS HIGH alarm issue will occur again since cylinder liners worn
are not replaced.
MHIET recommend to operate the engine with as high a load as possible.

Especially the operation with load 30% or less should be less than 10 minutes.
Recommendation about other point
The oil filter element should be replaced as soon as the alarm is activated.
There were cases that the oil filter element was not replaced immediately after L.O.
FILTER DIFF. PRESS HIGH alarm was activated, and the generator set was
continued operating at the differential pressure of 500 kPa or more.*1 At this time,
the lube oil pressure from the oil pump to the oil filter was more than 1 MPa. It is
possible that a lube oil leakage will occur with the lube oil filter assy.
*1 The measuring range of the differential pressure transmitter is from 0 to 500 kPa.
MHIET recommend to carry out the lube oil analysis at least every 250 hrs.
Because a sign of some failure can be found from the analysis result of used lube
oil. MHIET already found the possibility of the fuel dilution from the analysis result
of Kinetic viscosity.
Additional recommendation: Parts change (1/2)
MHIET recommend to change below parts because the average load of generator
set is low as 64.6 % that is a disadvantage to soot generation.
No. Parts Name Item Recommend part Current part
Part No. 41069-04302 41069-04202

1 Nozzle tip Nozzle port dia.: Nozzle port dia.:
Spec
0.35 mm *1 0.37 mm
Part No. To be decided 49129-35300

Ring nozzle of Nozzle area: Nozzle area:
2
Turbocharger Spec narrowing (under 36 cm2
consideration)
*1 A demerit of narrowing the nozzle port diameter is that risk of clogging nozzle tip,
rising fuel injection pressure, and damaging driving camshaft and tappet of fuel
injection pump increases. Please carry out the maintenance according to MHIET
recommended maintenance menu.
Additional recommendation: Parts change (2/2)
MHIET recommend to change the cylinder liner to make the engine harder to attach
the carbon than current when the cylinder liner will be replaced.
No. Parts Name Item Recommend part Current part
Part No. 41010-08101 41010-16105

3 Cylinder liner with Standard (without
Spec
Anti polish ring *1 Anti polish ring)
4 Anti polish ring Part No. 41010-08201 n/a

*1 There is no need to change the piston.

ETEESE17-1683 - Investigation Report Regarding Oil Filter Alarm of ERL S16U (06-Mar-2018)

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ETEESE17-1683 - Investigation Report Regarding Oil Filter Alarm of ERL S16U (06-Mar-2018)

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To: Mitsubishi Heavy Industries Enqine System Asia Pte. Ltd.

Investigation repo同about Lube oil main

Approved Check Author

About Maintenance work

Much carbon was adhered on the all nozzle tips.

Five nozzle tips had bad spray pattern.

Cyl Injection Spray condition Cyl Injection Spray condition

Three nozzle tips are clogged.

Carbon adhered condition in the Carbon adhered condition in the cylinder

No. Item Findings

• Much carbon was adhered on the all nozzle tips.

2 Combustion chamber • Much carbon was adhered in all cylinders.

• Much carbon was adhered on top and in ring

• Eight cylinder liners were scratched and worn by

• After maintenance black smoke decreased than

• After maintenance it decreased than before

Injection nozzle Spray condition

Injection timing is Measure injection All cylinder is 14

Turbocharger Check rotor of

Operation of under Long time operation with

Used hour of Oil & Element [hr]

Crankcase press [kPa]

Lube oil Filter element Alarm Crankcase press

Used hour of Oil & Element [hr]

Crankcase press [kPa]

Lube oil Filter element Alarm Crankcase press

1) Kinetic viscosity @ 100℃ [mm2/s] 2) TBN [mg KOH/g]

3) Pentane insoluble [wt%] 4) Condensation Pentane insoluble [wt%]

According to findings of Rank-E maintenance (top overhaul), the cause of L.O.

The maintenance should be carried out according to the MHIET recommended

MHIET recommend to replace the cylinder liner as soon as possible.

MHIET recommend to operate the engine with as high a load as possible.

No. Parts Name Item Recommend part Current part

Part No. 41069-04302 41069-04202

Part No. To be decided 49129-35300

No. Parts Name Item Recommend part Current part

Part No. 41010-08101 41010-16105

4 Anti polish ring Part No. 41010-08201 n/a

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