Gas Engines

Gas Engine Oil Design and

Development
ExxonMobil Is Committed To

• Maintain Gas Engine Oil market and technology

leadership and strengthen position through
– Highest quality products and relevant lubrication
services
– Lowest overall lubrication costs for customers

• Working with key gas engine builders, customers, etc

to develop step-out lubrication technology and
services
Product Development Cycle

Market Needs
> - Major EB
- Environment
>
Commercialization Development
(Bases
&
Additives Selection)
>

>
Field Testing > > Laboratory
Tests

Rig Testing
Gas Engine Manufacturers - on the move...
Caterpillar Inc. Cooper Energy Services
- Perkins - Ajax
- Dorman - Cooper Bessemer
- MaK - Enterprise
- INTAC (JV) - Superior
- Misubishi Heavy Industries (JV) - White
- Empressa Nacional Bazan Motores (JV)
Wärtsilä NSD
Dresser Industries GEC Alsthom - Wärtsilä Vaasa
- Ingersoll-Rand - Mirrless Blackstone - Wärtsilä SACM
- Clark - Paxman - Stork-Wärtsilä
- Worthington - Ruston - Wärtsilä Nohab
- Waukesha - Kelvin - New Sulzer Diesel
- Grandi Motori Trieste
- CWEC (JV with Cummins)
Coltec Industries
- Fairbanks Morse MAN Group
- ALCO - MAN Dezentrale Energiesysteme
- SEMT-Pielstick (licensee) - MAN B&W

Source: Oronite, Kevin D. Carabell

 OEM Requirements (4-Stroke Gas Engines)
OEM S-Ash Phosphorus TBN SAE Grade Comments
[wt%] [wt%] [mg KOH/g]

Caterpillar 0.4 - 0.6 - - 15W-40, 40, 30 API CC or CD, Field Trials (7000 hrs),
(0.4 pref.) no formal approvals

Deutz MWM Type D < 0.5 - >3 40 field trials (10000 hrs), approval lists
Type E 0.5 - 0.75 - >5 30, 40

Jenbacher leanox 0.6 - 1.0 - ~8 40 MIL-L-2104 B (L-2104 C pref.)

lamda 1 < 0.5 < 0.08 > 3, > 4 pref. 40 API CC, MIL-L-2104 B
landfill 0.6 - 1.0 - ~8 40 field trials (5000 hrs), approval list

MAN (MDE 0.4 - 0.7 - - 30, 40 field trials (5000 hrs), approval lists
Dezentr. Energ.syst.) for nat. aspir. and turbo. engines

MAN B&W < 1.0 - 4-6 40 API CD, MIL-L-2104 D, field trial 10000 hrs

Niigata Dual Fuel < 0.9 - 4-7 30, 40 ISOT, KHT, L-38, 4 Ball, 1G-2, field trial
Spark Ignit. < 0.6 - 3-7 30, 40

Wärtsilä NSD < 0.6 - 5-7 40 or Multigrade VI > 90, field trials (4000 hrs), approval list

Waukesha VSG,VHP,AT > 0.35 - - 30, 40 Zn < 0.1 wt%, API CD, field trial (4000 hrs)
VGF 0.5 - 1.0 - - 30, 40 approval lists for Cogen and Landfill
VHP leanburn 0.9 - 1.7 - - 30, 40 applications
Product Development Cycle

Market Needs
> - Major EB
- Environment
>
Commercialization Development
(Bases
&
Additives Selection)
>

>
Field Testing > > Laboratory
Tests

Rig Testing
Gas Engine Oil Design
Important Factors
• Crude Selection
• Stable Base Stocks
• Excellent Thermal Stability
• High Oxidation & Nitration Resistance
• Low Volatility
• Balanced Additive System
Factors Affecting Lubrication

• Quality of base oil

• Additive selection
• Sump size and oil consumption
• Fuel gas
• Engine operation
Lubricant Formulation
Bases classification

Group Sulfur, Weight Saturated V.I.

I >0.03 And / or <90 80 - 120

II ≤0.03 And ≥90 80 - 120

III ≤0.03 ≥90 >120

IV Polyalphaolefins (PAOs)

V Bases not included on groups I - IV

Base Stocks for Heavy Duty
Lubes Differences
Differences in
in Base
Base Stocks
Stocks

ExxonMobil
Base Stock Group I Group II
Group II+
Saturates Level Below 90% Above 90% Above 95%

Sulfur Level Above 0.03% Below 0.03% Below 0.01%

Viscosity Index 95 Typical 95 Typical Above 115

„ Group I stocks offer a benefit of improved deposit, particularly piston

cleanliness.

„ Group II+ stocks offer a benefit in soot dispersancy, especially at very

elevated soot levels. They also provide a benefit in oxidation stability.
Base Stock Comparisons
„ Many competitive products are formulated with essentially all Group II
(hydrocracked) base stocks

„ ExxonMobil products are formulated with an optimized blend of Group I &

Group II+ base stocks

Group I Group I Group II ExxonMobil

95 VI 95 VI 95 VI w/ Group II+
76% Saturates 82% Saturates 100% Saturates 91% Saturates
GEO Additive Components

• Ashless dispersants
• Detergents (Ash Content)
• Oxidation inhibitors
• Anti-wear and anti-scuff agents
• Corrosion inhibitors

• Need to ensure compatibility between each other and

the base oil
Product Development Cycle

Market Needs
> - Major EB
- Environment
>
Commercialization Development
(Bases
&
Additives Selection)
>

>
Field Testing > > Laboratory
Tests

Rig Testing
New Product Development

• Bench Testing

• Engine Testing

• Full Scale Engine Testing

• Field Testing

• Key engine builder approvals

Functions of GEO’s

• Oxidation & Nitration Control

• Reduction of Friction and Wear

• Prevention of Corrosion and Rust

• Engine Cleanliness
Gas Engine Oil Selection
Lubrication Requirements

Control of Spark Plug Fouling

(misfiring) Exhaust Gas (Control of Catalyst
Poisoning)

Optimised Ash Deposit

Control of piston ring wear &
(Valve recession, carbon deposit)
cleanliness (ring sticking, bore
polishing, oil consumption)

Control of liner Heat removal

wear/lacquer/corrosion (oil
consumption, engine life)
Lubrication & load Carrying
Properties (Reduce friction & wear) Oil Life
Control of Foaming/Volatility (Oxidation, Nitration, Lacquering,
Sludge Formation, viscosity increase,
(Oil consumption) TAN increase)
Critical Performance Parameters
• The severe operating conditions of a gas engines require
– excellent oxidation inhibition and nitration resistance
– improved piston cleanliness and low deposit formation
– no valve recession and improved scuff protection
– low oil consumption and controlled viscosity increase
– reliable corrosion control in bio-gas applications
– optimized oil drain intervals

• Therefore specialized products are needed for the lubrication of

gas engines
– How do you choose one?
Classifications of Gas Engine Lubricants

Although there are no API classifications applicable

to natural gas engine oils, the following table
specifies these lubricants by percentage of ash
content.

Ash-less < 0.1%

Low Ash 0.1 - 0.5%
Medium Ash 0.5 - 1.5%
High Ash > 1.5%
Product Selection
• No universal industry performance specifications as
with automotive oils
• Major EBs require satisfactory performance
successfully demonstrated in field test engines
• Most EBs have established oil selection guidelines
– physical and chemical properties
– proven field service
• Mostly 30 and 40 monogrades recommended
• Key selection criteria are based on viscosity,
sulphated ash and TBN characteristics
GEO Selection
• Type Of Engine
– Application
– Duty Cycle

• Type Of Gas
– Level of Contaminant e.g. water, solids, sulphur,
halides

• Type of Lubricant
– Sulphated Ash Level
– Type of Additive Technology
Selecting The Right Gas Engine
Oil
• Engine manufacturer’s recommendation
– Engine type
– Lean burn or stoichiometric, catalyst?
– Sump size
• Consider operation
– Extended oil drain intervals?
– Oil consumption (high ---> low SASH)
• Establish optimum oil drain interval
– EB recommendation and used oil analysis data
– There are NO standard oil drain intervals
GEO Selection - Engine Issues
• Valve Recession
• Oxidation
• Nitration
• Corrosion
• Scuffing
• Spark Plug Fouling
• Exhaust Port Blockage (2 cycle)
• Organic Halides
Engine Issues (Con’t)

• The higher combustion temperatures cause

chemical oxidation and nitration to occur within
the oil.
• Operating speed is generally constant,
therefore these engines are prone to deposit
formation.
• Exhaust valve recession and/or burning is a
major concern in natural gas engines.
Valve Recession

Is the gradual wearing of the valve into the head

caused by insufficient lubrication, or insufficient "ash"
deposit "cushioning" the valve seat area.

Frequently, a valve may also suffer damage called

guttering, which is a deep channel cutting across, or
into, the valve seat area.

The causes of these conditions are many and varied

and can be quite different, depending upon the
engine design.
 Considerations When Investigating
Valve Recession
The following factors should all be considered, when
investigating the root cause of an exhaust valve failure.
• Lubricant formulation (as it relates to ash deposits)
• Viscosity
• Operating temperatures
• Exhaust gas temperatures
• Natural gas fuel quality
• Engine design characteristics
• Air fuel ratios,
The issue of ash deposits in particular is much discussed
among operators of natural gas engines.
Oxidation

• Occurs When Oil Combines With Oxygen Under

Certain Conditions to Form a Wide Variety
of Oxidation Products.
• Once Initiated a Chain Reaction Occurs Which
Can Rapidly Destroy an Oil's Usefulness.
• Oxidation Products Form Lacquer Deposits,
Corrode Metal Parts, Thicken Oil Beyond its
Ability to Lubricate, and Cause Accelerated
Wear.
Oxidation (Con’t)

Causes:
z Overheating
z Overextended Oil Drains
z Improper Oil Types
z Excessive Blowby
z High Sulphur Level
 Nitration

• Nitration is a chemical reaction within the oil which takes

place as nitrogen dioxide (N02) compounds bond with
hydrocarbon chains and cause severe oil thickening and an
increase in varnish and sludge.

• Nitration becomes significant at oil reservoir temperatures

around 57'C (135F) and becomes even
more dramatic at lower temperatures.
Nitration (Con’t)

• This is very different from oxidation formation, which

becomes significant as oil temperatures increase
above 95'C (200'F).

• Nitration of the oil is a much more significant

problem in natural gas engines than in diesels. This
is due to the higher temperatures caused by the
combustion process.
Nitration (Con’t)
Heavy Orange-Maroon Coloured Lacquer due to
Nitration
 Ash Deposits

• They are the residue remaining after the oil is burned

during operation.

• The ash residue is made up of metallic detergent

additives, such as calcium, barium and magnesium
compounds.
Ash Deposits (Con’t)
• These ash deposits, if adequate, can prevent valve
recession, however if the ash content is too high, the
result will be unwanted and harmful deposits.

• Consequently, lubricant manufacturers and blenders

usually take great care that the proper selection and
quantities of anti-wear and detergent additives are
applied when formulating natural gas engine oils, The
selection and application must also always take the
engine manufacturer's recommendations into
account.
Sulfated Ash

INCREASE BETTER PERFORMANCE MORE DEPOSITS

(Good Piston Cleanliness) (Pre-ignition)

DETERGENT- SULPHATED
ADDITIVES ASH

REDUCED PERFORMANCE LESS DEPOSITS

DECREASE (Danger: Ring Sticking)
Sulphated Ash (Con’t)
Increased Deposits,
Balanced Reduced Wear
condition
Sulfated Ash

Reduced Deposits,
Increased Wear

Operating Hours

Therefore the optimum SASH level is important in selecting the right

gas engine oil :
2T Gas Engines: ashless to low ash
Natural Gas, Catalyst : low ash
Biogas, Dual Fuel: medium ash
Sulphated Ash (Con’t)

• Major Ash Deposits

Causing Plug Fouling
Gas Engine Oil ( GEO )
Classifications
• Ashless
– Sulphated Ash ( SA ) <0.15%
• Low Ash
– SA 0.15 to 0.6 %
• Medium Ash
– SA 0.6 to 1.0%
• High Ash
– SA > 1.0%
Lubrication Functionality in
Gas Engine Oils
Engine Components

• Pistons
• Cylinders or Liners
• Bearings
• Ports
• Heads/ Valves
• Crankshafts
• Turbochargers
• Camshafts
 Pistons, Rings

• Piston Cleanliness
• Rings Free
• Undercrown Deposit
Test Oil Quality (thermal
stability)
Cylinders, Liners

Keys:
• Maintain Profile
• Avoid Scoring
• Avoid Cavitation
• Help Seal
Combustion Gases
Engine Bearings
Rod Bearings
• Connecting Rod
Bearings
– Tri Metal: Lead,
Copper, Tin, or
Aluminum
• Main Engine Bearings
– Tri Metal: Lead,
Main Bearings Copper, Tin, or
Aluminum
• Rolling Element
Bearings
– Brass, Iron
Heads, Valves

• Ash Protects Face/Seat

from Beat-In
• Too Much Ash is Bad
Oil Consumption vs. Ash
Content
Products
New Gas Engine Oil Naming
System

• The Pegasus name remains the stem for Mobil gas

engine oils - the synonym for leading product
technology!
• What is new?
• A new three digit system which offers:
• Quality level indication
• Indication of ash level to support correct product
selection
• delivers world wide consistency
New Gas Engine Oil Naming System
Current/Future Product Line
Type < 0 .1 % < 0 .5 % < 1% > 1%
Ash Ash Ash Ash
S y n t h e t ic s Pe g a s u s 1 Pe g a s u s
SH C
E x t r a H ig h Pe g a s u s
P e rfo rm a n c e 905
u n d e r fie ld te st
H ig h Pe g a s u s Pe g a s u s Pe g a s u s
P e rfo rm a n c e 801 805 8 10
Pe g a s u s 10 0 / 4 0 n e w Pe g a s u s 8 0 new P 489 c a nd .
P e rfo rm a n c e Pe g a s u s Pe g a s u s Pe g a s u s Pe g a s u s
G ra d e s 701 705 7 10 7 15
Pe g a s u s 9 0 Pe g a s u s 8 0 / 4 8 0 Pe g a s u s 4 8 9 Pe g a s u s 4 5 0
B io & S p e c ia l G a s Pe g a s u s Pe g a s u s
G ra d e s 605 6 10
Pe g a s u s 4 2 6 Pe g a s u s 4 4 6
S ta n d a rd Pe g a s u s
G ra d e s 505
Pe g a s u s 4 8 5
ExxonMobil Performance Objective*

CAT Engine Models Mobil Pegasus 905

G3400 series 1,500 hours
G3500 series 2,000 hours
G3600 series 8,000 hours

* There is potential for further extended drain capabilities, provided the used
oil analysis program, good fuel gas and engine operation/maintenance.