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Service/Parts Topics Date: Application: 02.02.2009 Generator Unit No: Fuel Type: File Group

Service/Parts

Topics

Date:

Application:

02.02.2009

Generator Unit

No:

Fuel Type:

File Group

ESB-SPB 22.2

Natural Gas

07

CUMMINS CONFIDENTIAL ESB Internal Circulation, Approved Distributors and Partners Only

Author:

A. Kitchen

 

Subject:

Oil Analysis Guidelines

 
 

Publications Affected by This Service/Parts Topic

 

Engine

Operation and Maintenance

Troubleshooting and Repair

Shop

Other

QSV81G/91G

4021313

     

NOTE: Publications identified as Other include the following: ¹Parts Catalogue, ²Wiring Diagram.

 

This Service Bulletin applies to QSV81G/QSV91G 14 and 16Bar BMEP, QSV91G 18Bar BMEP 2MWe and QSK60G Gensets as indicated in the table below. The bulletin also details condemning limits for the K38 Natural Gas Power Generation Product manufactured in India.

Engine

Speed (rpm)

Freq.

Model Rating

Genset Model Covered By Service Topic

(Hz)

QSV 91G

 

1200

60

1250GQNA

Yes

QSV 91G

 

1500

50

1540GQNA

Yes

QSV 91G

 

1500

50

1750GQNB-50

Yes

QSV 91G

1500

(gearbox)

60

1750GQNB-60

Yes

QSV 91G

 

1500

50

2000GQNC-50

Yes

QSV 91G

1502

(gearbox)

60

2000GQNC-60

Yes

QSV 81G

 

1200

60

1200GQMA

Yes

QSV 81G

 

1500

50

1370GQMA

Yes

QSV 81G

 

1500

50

1570GQMB

Yes

QSK 60G

 

1200

60

1000GQKB

Yes

QSK 60G

 

1200

60

1100GQKC

Yes

QSK 60G

 

1500

50

1160GQKA

Yes

QSK 60G

 

1500

50

1400GQKC

Yes

QSK 60G

 

1800

60

1400GQKA

Yes

QSK 19G

 

1500

50

315GFBA

No

QSK 19G

 

1800

60

330GFBA

No

Service/Parts Topics Date: Application: 02.02.2009 Generator Unit No: Fuel Type: File Group

Service/Parts

Topics

Date:

Application:

02.02.2009

Generator Unit

No:

Fuel Type:

File Group

ESB-SPB 22.2

Natural Gas

07

Warranty Impact

Regular Oil Analysis forms a very important part of the engine’s service and maintenance regime. The oil change intervals quoted in the relevant Operation and Maintenance Manuals are maximum oil change intervals and are subject to the oil analysis results.

It is important to understand that the Genset must be serviced and maintained in accordance to Cummins published recommendations. Whilst failing to carry out regular oil analysis will not void Cummins warranty, it must be understood that Cummins will deny coverage for any corrective work or progressive damage that Cummins alone determines was caused by not undertaking regular Oil Analysis as well as failure to carry out appropriate action as indicated by the Oil Analysis results, or by continuing to operate an engine with an oil that is deemed not fit for further use.

The information contained within this Service Bulletin does not authorise TRP or Campaign practices.

The purpose of this Service Bulletin is to define Cummins guidelines for the oil analysis of Natural Gas fuelled Gensets. Specifically, it defines the oil analysis interval, as well as the caution limits and condemning limits for the engine oil.

Service/Parts Topics Date: Application: 02.02.2009 Generator Unit No: Fuel Type: File Group

Service/Parts

Topics

Date:

Application:

02.02.2009

Generator Unit

No:

Fuel Type:

File Group

ESB-SPB 22.2

Natural Gas

07

Document Overview

The purpose of this Service Bulletin is to define Cummins guidelines for the oil analysis of Natural Gas fuelled Gensets. Specifically, it defines the oil analysis interval, as well as the caution limits and condemning limits for the engine oil.

This Service Bulletin does not define an approval procedure for new oil selection; for oil approval refer to Cummins Engineering Standard 14615. This Bulletin assumes that the oil being used has already been approved by Cummins Inc.

This Service Bulletin does not aim to give advice on causes of oil deterioration or corrective action.

Definitions

Caution Limit: An indication that the engine oil is approaching end of life.

Condemn Limit: An indication that the engine oil has reached its end of life. This level must not be exceeded. Continued operation beyond the Condemning Limit may cause serious engine damage and invalidates the engines warranty.

Oil Analysis

The variation in oil brands, base stocks, additive packages, gas quality, climate conditions, Genset load factors, engine condition and other influences necessitate the use of Oil Analysis to maximize life cycle cost and engine reliability.

The intervals, methods and limits described below are based on operating experience, oil supplier guidelines, oil analysis laboratory guidelines and other data sources. Specific site experience and the use of more advanced analysis techniques may allow scope for adjustments to the recommendations below. However, any change must be approved through Cummins Inc before being implemented.

Failure to follow these guidelines may cause engine damage and invalidate the engines warranty.

Oil Sample Frequency

Natural Gas Fuelled Generator Sets

Until the oil change interval is established, the oil analysis frequency should be at a maximum of each 250 operating hours or 6 months, whichever occurs first. Once the oil change interval has been established, the analysis frequency may

Service/Parts Topics Date: Application: 02.02.2009 Generator Unit No: Fuel Type: File Group

Service/Parts

Topics

Date:

Application:

02.02.2009

Generator Unit

No:

Fuel Type:

File Group

ESB-SPB 22.2

Natural Gas

07

be extended to a maximum of 20% of the change interval, or 6 months, whichever occurs first.

Low Btu (Landfill and Biogas Fuelled) Applications

For Low Btu (Landfill and Biogas Fuelled) applications, the oil analysis frequency should be at a maximum of each 168 operating hours or every two weeks, whichever occurs first.

IMPORTANT NOTE: Where regular Oil Analysis is not performed, then the oil change interval published in the appropriate engine Operation and Maintenance manual must be reduced by 50%.

NOTE: Where regular Oil Analysis is not performed, then an ‘end of oil life’ analysis must be carried out immediately prior to each oil change to determine that the oil was within the limits (shown on Table 1 below) and still fit for use.

Oil Sample Baseline

As key elements of the Oil Analysis are based on a change from fresh oil it is essential that a baseline fresh oil sample is first established. This must be of the oil supplier, oil grade and source used in the engine and analysed by the analysis laboratory chosen for the ‘used oil analysis.’ This baseline should normally be managed between the oil supplier and the analysis laboratory, but this should not be presumed. Fresh oil sample analysis must be repeated for any oil formulation or analysis change.

Oil Sampling

The used oil sample taken for analysis must be representative of the oil in the engine. Use the following guidelines when collecting used oil samples:

Bring the engine up to normal operating temperature prior to sampling. This will ensure the representative contaminant levels are in the sample. Take the used oil sample before adding any fresh oil to the engine. Take the used oil sample either directly from the engines sump or from a suitable sample point before the oil filters. Always collect the oil in a dry, clean container and collect a minimum of 0.125 Litre of oil.

The following information should also be supplied:

Engine make, type and serial number.

Type of use, duty cycle and fuel type.

Sample date, sample conditions (intermediate, at oil change, etc.).

Service/Parts Topics Date: Application: 02.02.2009 Generator Unit No: Fuel Type: File Group

Service/Parts

Topics

Date:

Application:

02.02.2009

Generator Unit

No:

Fuel Type:

File Group

ESB-SPB 22.2

Natural Gas

07

Engine oils, oil hours, hours since last analysis and oil top-up since last analysis. Oil manufacturer, type and viscosity.

Note: Oil manufacturers/suppliers can usually provide suitable oil analysis kits.

Table 1: Oil Caution and Condemning Limits

QSV Engine Range:

Engine

Characteristic

Units

Caution Limit

Condemning Limit

Model

QSV

TBN

g(KOH)/kg

40% reduction from fresh oil

50% reduction from fresh oil

QSV

TAN

g(KOH)/kg

2.0

increase from

2.5

increase from fresh oil

fresh oil

QSV

Oxidation

Abs/cm

 

15

 

20

QSV

Nitration

Abs/cm

 

10

 

15

QSV

Viscosity

Cst at 100° C

2.0

increase from

2.5

increase from fresh oil

fresh oil

QSV

Aluminium (Al)

ppm

 

10

 

15

QSV

Chrome (Cr)

ppm

 

3

 

5

QSV

Copper (Cu)

ppm

 

10

 

15*

QSV

Iron (Fe)

ppm

 

15

 

20*

QSV

Lead (Pb)

ppm

 

10

 

15

QSV

Silicon (Si)

ppm

 

10***

 

15***

QSV

Tin (Sn)

ppm

 

5

 

10

QSV

Calcium (Ca)

**

 

**

 

**

QSV

Zinc (Zn)

**

 

**

 

**

QSV

Phosphorous (P)

**

 

**

 

**

QSV

Boron (B)

**

 

**

 

**

QSV

Sodium (Na)

ppm

 

10

 

15

QSV

Water (H2O)

%

 

0.2

 

0.2

NOTE: Where oil analysis confirms the source of Copper and Iron is not bearing related, the condemning limits may be increased to 60ppm for Copper and 80ppm for Iron.

** NOTE: Ca, Zn, P and B are used in the oil additives package for protection against acid build-up and wear. The levels do vary between oil suppliers and may not be published. It is recommended to seek advice on Caution and Condemning Limits for these elements based on a change from the fresh oil sample and agreed with the oil supplier.

*** NOTE: For Low Btu (Landfill and Biogas) applications, the Silicon (Si) Caution Limit can be increased to 150ppm and the Condemning Limit can be increased to

180ppm.

Service/Parts Topics Date: Application: 02.02.2009 Generator Unit No: Fuel Type: File Group

Service/Parts

Topics

Date:

Application:

02.02.2009

Generator Unit

No:

Fuel Type:

File Group

ESB-SPB 22.2

Natural Gas

07

NOTE: Low Btu (Landfill and Biogas) applications only; Chlorine (Cl) should be monitored. The Caution Limit is 1000ppm and the Condemning Limit is 1400ppm.

QSK60G Engine Range:

Engine

Characteristic

Units

Caution Limit

Condemning Limit

Model

QSK60G

TBN

g(KOH)/kg

40% reduction from fresh oil

50% reduction from fresh oil

QSK60G

TAN

g(KOH)/kg

2.0

increase from

2.5

increase from fresh oil

fresh oil

QSK60G

Oxidation

Abs/cm

 

15

 

20

QSK60G

Nitration

Abs/cm

 

10

 

15

QSK60G

Viscosity

Cst at 100° C

2.0

increase from

2.5

increase from fresh oil

fresh oil

QSK60G

Aluminium (Al)

ppm

 

10

 

15

QSK60G

Chrome (Cr)

ppm

 

3

 

5

QSK60G

Copper (Cu)

ppm

 

10

 

15*

QSK60G

Iron (Fe)

ppm

 

15

 

20*

QSK60G

Lead (Pb)

ppm

 

10

 

15

QSK60G

Silicon (Si)

ppm

 

10

 

15

QSK60G

Tin (Sn)

ppm

 

5

 

10

QSK60G

Calcium (Ca)

**

 

**

 

**

QSK60G

Zinc (Zn)

**

 

**

 

**

QSK60G

Phosphorous (P)

**

 

**

 

**

QSK60G

Boron (B)

**

 

**

 

**

QSK60G

Sodium (Na)

ppm

 

10

 

15

QSK60G

Water (H2O)

%

 

0.2

 

0.2

* NOTE: Where oil analysis confirms the source of Copper and Iron is not bearing related, the condemning limits may be increased to 60ppm for Copper and 80ppm for Iron.

** NOTE: Ca, Zn, P and B are used in the oil additives package for protection against acid build-up and wear. The levels do vary between oil suppliers and may not be published. It is recommended to seek advice on Caution and Condemning Limits for these elements based on a change from the fresh oil sample and agreed with the oil supplier.

Service/Parts Topics Date: Application: 02.02.2009 Generator Unit No: Fuel Type: File Group

Service/Parts

Topics

Date:

Application:

02.02.2009

Generator Unit

No:

Fuel Type:

File Group

ESB-SPB 22.2

Natural Gas

07

K38 Natural Gas Power Generation Product (Manufactured in India):

Engine

Characteristic

Units

Caution Limit

Condemning Limit

Model

K38G

TBN

g(KOH)/kg

40% reduction from fresh oil

50% reduction from fresh oil

K38G

TAN

g(KOH)/kg

1.5

increase from

2.0

increase from fresh oil

fresh oil

K38G

Oxidation

Abs/cm

 

10

 

15

K38G

Nitration

Abs/cm

 

10

 

15

K38G

Viscosity

Cst at 100° C

2.0

increase from

2.5

increase from fresh oil

fresh oil

K38G

Aluminium (Al)

ppm

 

3

 

5

K38G

Chrome (Cr)

ppm

 

11

 

14

K38G

Copper (Cu)

ppm

 

15

 

20*

K38G

Iron (Fe)

ppm

 

15

 

20*

K38G

Lead (Pb)

ppm

 

7

 

10

K38G

Silicon (Si)

ppm

 

15***

 

20***

K38G

Tin (Sn)

ppm

 

15

 

20

K38G

Calcium (Ca)

**

 

**

 

**

K38G

Zinc (Zn)

**

 

**

 

**

K38G

Phosphorous (P)

**

 

**

 

**

K38G

Boron (B)

**

 

**

 

**

K38G

Sodium (Na)

ppm

 

11

 

15

K38G

Water (H2O)

%

 

0.2

 

0.2

* NOTE: Where oil analysis confirms the source of Copper and Iron is not bearing related, the condemning limits may be increased to 60ppm for Copper and 80ppm for Iron.

** NOTE: Ca, Zn, P and B are used in the oil additives package for protection against acid build-up and wear. The levels do vary between oil suppliers and may not be published. It is recommended to seek advice on Caution and Condemning Limits for these elements based on a change from the fresh oil sample and agreed with the oil supplier.