Development of Lubricating Oil Degradation Model for Engine Health Monitoring

By
Chan Wen Xiang, Som-Sak

Supervised by
A/Professor Ng Chunwee

An Interim Report submitted in

fulfilment of the partial requirements
for the degree of
Bachelor of Engineering in
Naval Architecture & Marine Engineering
Newcastle University & Singapore Institute of Technology
November 2024

Declaration
No part of the work presented in this report has been submitted in support of an application for another
degree or qualification of this or any other university or other institute of learning.

Confidentiality
If your work is confidential, you should declare here.
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ABSTRACT deterioration. This data enables engineers to identify early

Technical failures are a major cause of incidents in the indicators of future problems, facilitating proactive
marine industry, with machinery damage and failures maintenance and modifications that enhance the engine's
among the most common. This interim report investigates efficiency, durability, and general dependability.
the principal sources of wear and tear that may result in
accidents, assessing these aspects to assess the probability The aim of the study is to develop a model of lubricating
of such occurrences. The project aims to develop a oil degradation monitoring in marine engines using already
comprehensive warning system combining preventative, existent industry technology. The establishment of this
corrective, and risk-based maintenance strategies. Using continuous monitoring system will enable preventive
Data-Driven Condition-Based monitoring (DCBM) and maintenance; thus, reducing wear on the engine reducing
advanced analytics, the system seeks to detect issues early costs increasing operational efficiency while potentially
and enable targeted interventions. A lubricating oil extending oil change intervals. With a focus on
degradation model, incorporating physics and chemistry development of this model to address the need for scalable
principles, to enhance engine health monitoring, improve sustainable practices in the industry following recent
operational reliability, and reduce costs in line with the advancements in the digital age and intelligent
industry’s shift towards digitalization and intelligent maintenance within the industry.
maintenance.
2. Categories of Maintenance
Keywords Actions are maintained based on the motivation behind
Marine incidents, Machinery Failure, Comprehensive each action; this is the classification of maintenance. There
Warning System, DCBM, Lubricating Oil Degradation, are two planned principal categories: preventive
Digitalization and Intelligent Maintenance maintenance (PM) and corrective maintenance (CM).
(Jaramillo Jimenez et al., 2020). As shown in Fig. 1,
Preventive Maintenance refers to those approaches to avoid
1. Introduction
equipment failure by means of proactive strategies such as
In the marine industry, minimizing downtime and the
Condition Based Maintenance (CBM), which acts based on
Operational Expenses (OPEX) requires reliable and
observed equipment conditions or on Predictive
efficient engine maintenance. Traditionally, Planned
Maintenance (PM) which predicts conditions based on a
Maintenance (PM) is based on manual inspections and
deterioration trend by using past failure trend with data
using schedules given by manufacturers, there is no real
analytics. In addition, Risk Based Maintenance determines
time monitoring or predictive diagnostics. Consequently, it
potential risks and acts to where failure will have the most
may increase OPEX by allowing the probability of
serious consequences, instead of implementing those
incomplete maintenance due to unobserved early warning
maintenance activities where failure is probable. The
indicators of degradation of component to be excessive or
methods bring out different objectives to facilitate
inadequate.
equipment reliability and longevity.
The application of predictive models to Condition Based
Monitoring (CBM) is made possible by the advances in
data analytics. With CBM’s focus on real time condition
data, instead of fixed schedules, operators can adjust to
current equipment health status rather than sticking on
fixed schedules. Enhanced predictive skills can help CBM's
with decision making by being able to foresee likely
problems before these problems grow into expensive
repairs or complete failure.

Cast steel is widely used for critical components such as

piston liners due to its excellent mechanical properties.
Cast steel contains the main alloying element carbon, and
is composed principally of iron, having a carbon content in
the range usually between 0.1% and 0.5%. The carbon
content in this material is important for defining the
material’s hardness and strength. Incorporated usually are
additional alloying elements, such as silicon, manganese, Fig. 1. This is an Overview of the Types of Maintenance
chromium, nickel and molybdenum designed to meet
certain performance needs. Silicon increases fluidity 2.1 Preventive Maintenance
during casting, manganese improves strength and Preventive Maintenance (PM) is defined as “Maintenance
toughness, chromium and nickel provide corrosion carried out at predetermined intervals or according to
resistance, and durability (Soars J Edmo, 2016). For prescribed criteria and intended to reduce the probability of
various engine operational conditions, the steel can be failure or the degradation of the functioning of an item”.
optimized by adjusting the precise balance of these (ISO, 2016) Routine inspection and maintenance of sea
elements. Engineers can improve and optimize engine equipment is considered as preventive maintenance aimed
performance by meticulously monitoring these at preventing unexpected failures, as well as effective
percentages, which offer essential insights into the pace of
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operation. Scheduled maintenance is a way to detect and unnecessary maintenance, downtime and optimises
fix minor problems early before they develop into worse, operational cost. It is used widely in modern shipping as it
big problems that cause downtime and expensive repairs. allows improvement of the general efficiency and
This enhances the dependability and efficiency of essential sustainability of maritime operations while aligning the
maritime assets. practise of maintenance with industry standards and with
minimum regulatory requirements. These may in fact work
This approach includes a few key activities like lubricating proactively with preventative maintenance to optimize
the moving parts, replacing worn components, inspecting operational efficiency.
for corrosion and calibrating equipment to make sure they
operate in conformity with operational standards. And in a 3. Categories of Analysis
marine environment with equipment hammered by high Preventive maintenance checks help in preventing any
humidity, salt exposure, and continuous use, wear and tear aspect of machinery from failing to last until its last day
accelerates. A preventive maintenance schedule will possible since maintaining with the preventive check
establish the lifespan of equipment, enhance the overall earlier will keep it dependable in working after the repair.
safety for crew and passengers, and for the duration of time The model must be designed such that adequate capacity
for the operation to be carried out with greater efficiency. can be maintained in lube oil systems to operate optimally.
Regular monitoring and maintenance is necessary in order
2.2 Corrective Maintenance for the system to be able to provide the right amount of
Corrective Maintenance (CM) is defined as “Maintenance lubricating oil at proper pressures. Preventative practice
carried out after fault detection to effect restoration”. On helps to make sure the system is operated inside of the
maritime vessels, it is the location where repairs and design parameters and has resultant lower wear and tear on
interventions are conducted to rectify issues arising from mechanical components thus increasing the overall
faults or failures. Corrective maintenance is the opposite of equipment longevity.
the preventive maintenance that is meant to prevent
problems; corrective maintenance reacts to problems when As shown in Fig. 2, among the components of preventative
they arise. For vessel operations, the approach is crucial as maintenance are lube oil sample analysis to identify
it enables immediate response to unaccounted breakdowns, contaminants and oil condition, as well as oil sampling and
mere negative operational downtime and minimizes the monitoring in the machine components. The elements that
chances of safety incident. were common in almost all the failures in my earlier
experience indicate operational inefficiencies or impending
A proper corrective maintenance strategy requires a good failures, like the presence of wear metals, water, and fuel
detection system and a quick action. Computerized contamination in particular: Heavy fuel oil (HFO) traces.
maintenance management systems (CMMS) are commonly Regular monitoring of the system allows early detection of
used by most vessels to log faults, track repairs required the contaminants so that timely corrective actions can be
and replacement parts. Corrective maintenance can be taken to maintain integrity and consistent performance in
expensive, particularly if the equipment should need to be the system under demanding operational conditions.
sent out for repair of major systems, but it can also inform
us as to frequent culprits and what is going on inside our
equipment to allow us to improve our future designs and
take preventative measures. (Vo Trong et al., 2011) Marine
operators have to balance between corrective and
preventive maintenance; if there is too much corrective
maintenance this will increase risks and costs at the same Fig. 2. These are the Key Monitoring Points for
time too much preventive maintenance will allocate 2 Stroke Engine
unnecessary resources.
3.1 Engine Model, Designed Limit
2.3 Risk-based Maintenance Any of the aspects of machinery can only be assessed if the
Risk Based Maintenance (RBM) is a proactive strategy purpose of the machinery is known. Evaluation of previous
where the potential risks to the marine machinery are performance data and maintenance records of the same
identified and then methods evolved to eliminate those, to equipment or analogous engines made by same producer is
protect the safety and reliability of the equipment. Instead equally important. Providing critical information on the
of using traditional time based or reactive approaches, it machinery’s operational reliability, prospective problems,
prioritises its maintenance tasks based on equipment failure and anticipated performance on a wide range of conditions,
probabilities and its consequences. RBM looks at critical these records can provide helpful information towards the
components that could impact vessel operations, safety or design of future turbine engine warranties as well as argue
environmental compliance and focuses resources on failure cases regarding previous machinery warranty claims. Such
risks were highest. information is the solid foundation for the evaluation of the
machinery's capabilities and the alignment with operational
By merging condition monitoring methods, such as requirements.
vibration analysis, thermal imaging, and oil analysis, with
legacy and predictive modelling, combine methods for Extended and severe uses of engine lead to inevitable wear
tracking machinery health and predicting possible and tear on critical onboard gear. Establishing operating
problems. RBM targets high risk areas and reduces
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"redlines"—limits of performance on equipment that guard downtime, and improved engine performance by giving
against hazards based upon a historical record and previous early alerts of possible problems. Oil analysis combined
performance data—is essential to mitigating hazards. with data-driven methods promises increasingly more
These redlines provide a blueprint that ensures that the precise and timely insights on engine condition as
machinery works within safe prosperities, reducing the technology develops, which will ultimately result in more
chances of an unexpected break down. Active use of effective and economical operations.
performance history to develop maintenance schedules,
upgrade or replacement of machinery can add years to the
life of the machine, improve safety and sustain the overall
operational efficiency.

3.2 Lubricating Oil Analysis

Lubricating oil analysis has emerged as one of the most
important methods for monitoring engine health and
forecasting possible breakdowns. Engineers can acquire
significant insights on the health of engine components and
overall engine performance by studying the physical and
chemical properties of used engine oil, as well as analysing
contaminants of wear particles in the oil. This analysis has
evolved into a vital tool for anticipating engine
maintenance and detecting problems early on.

This literature review studies how lubricating oil analysis,

specifically Used Oil Analysis (UOA) and Scavenge Drain
Analysis (SDA), provides information on engine health.

UOA is used to analyse the condition of both the

lubricating oil and the engine itself. By inspecting the oil
for contaminants and indications of equipment wear, UOA Fig. 3 This is a schematic Drawing of
guarantees that the lubricant is functioning properly and Scavenge Drain Oil Sample
can detect possible mechanical faults before they become
severe failures. This analysis including numerous variables 3.3 Lube Oil and Sample
to evaluate engine health. (TRIBOCARE, n.d.) Sampling and analysing equipment Lube oil is among the
key requirements of preventive maintenance on marine
Viscosity: Changes in viscosity may indicate aboard gear. Lubricating oil serves as the strategic fluid in
contamination or degradation of the oil, potentially equipment to reduce or prevent friction, heat and wear.
increased in wear and reduced engine efficiency. However, it may warp or have potential to be stained by
Base Number (BN): BN measures the oil’s ability to water, gasoline or particle matter, which again reduces its
neutralise acids. Declining BN suggest increased corrosion efficiency and endangers machinery. Through proper
risk. condition control—using cleaned tools, taking samples
Element Analysis: Detecting wear metals iron, copper and from specific ports, etc., and sampling the oil at optimum
aluminium can indicate specific component wear within operating conditions, operators can obtain accurate
the engine. representations of the current lubricant oil status.
Particle Count: Increased particle counts may indicate Mislabelling and missing documentation promote
accelerated wear or contamination. distortion, making it easier to track the state of machinery
health changes with time.
Overall, UOA can give crucial insights into equipment,
allowing prospective performance concerns to be identified After taking the sample, lubricant oil is analysed
before they become problems. comprehensively in order to determine a presence of any
contaminants, degradation, or first signs of mechanical
Shown in Fig. 3, SDA is a specialised oil analysis that
commonly used to monitor wear and cylinder oil utilisation
on individual units (MAN Energy Solutions, 2023) and to
estimate the Iron (Fe) content and BN content in the
cylinder drain. SDA is useful to monitor the cylinder Fig. 4 This is the overview of Iron Wear Rate
condition closely such as to control the wear of cylinder
liner, optimising both cylinder oil feed and overhaul wear. Viscosity and particle counting reveal contamination
intervals. It can also be used for early detection of cold or wear metals while spectroscopy can help with impurity,
corrosion caused by sulfuric acid. spectroscopy. These allow operators to identify problems
early enough so that the issues do not have to assemble,
To summarise, both UOA and SDA have demonstrated thus decreasing time and money required for repairs. It
themselves to be very useful techniques for evaluating delivers better operational readiness, as well as providing
engine health. It enables proactive maintenance, less
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longer equipment life, and reliable performance, thus

solidifying oil analysis as a foundational modern boat 4.1 Engine Model Design
maintenance effort. The design of 2 stroke marine engine model for lubricating
oil degradation will be using OCTAVE. Leveraging on its
3.4 Key Indicators of Engine Health using Marine computational capabilities and built in functions. The
Lubricating Oil Analysis model is able to simulate the degradation process of
Iron (Fe) cylinder lubricating oil over time.
Iron is the primary material used for cylinder liners in
marine 2 stroke engine due to its capabilities of heat Input parameters for the model includes:
dissipation, exceptional lubricating, wear resistant qualities  Engine Running Hours
Hardness and thermal conductivity (Thiagarajan et al.,
 RPM & Load
2020). During operation, inevitably, iron particles are
 Cylinder Bore Diameter and Stroke Length
released into the lubricating oil due to wear and tear.
Monitoring it through Scavenge Drain Analysis (SDA)  Initial Lubricating Oil Properties (Viscosity, Base
provides insights into the health of the cylinder liners and Number and Iron Content)
piston ring. As shown in Fig. 4, early detection of  Cylinder Oil Feed Rate
accelerated iron content allows timely interventions  Combustion Temperature and Pressure
preventing localise damaged and costlier repairs
By initialising these parameters and define functions,
Heavy Fuel Oil (HFO) OCTAVE can simulate various degradation processes.
Heavy Fuel Oil content in cylinder lubricating oil is another These functions involve physics and chemistry principles
key factor in monitoring the engine health. According to to model the changes in oil properties over time, such as
(Anish 2019), HFO contains various impurities such as changes in viscosity, base number depletion and increasing
sulfur, vanadium, sodium and metallic residues to the in contaminant.
lubricating oil, degrading its performance. It could also
lead to acid formation, deposit formation and abrasive 4.2 Model Validation
wear, degrading the engine performance. To ensure the reliability and accuracy of the lubricating oil
degradation model, a verification process is essential. This
3.5 Summary of Key Findings: process compares the model’s outputs with real world data
The literature review above highlights the advancement in to validate its performance and applicability for the future
maintenance strategies, on how have we significantly marine engine health monitoring.
improved from conventional method to predictive and
preventive to improve the reliability and efficiency of Verification of Viscosity
marine engine. Also, techniques such as UOA and SDA The model ability to predict changes in the oil viscosity
have proven to be effective to identify early signs of wear over a period and will be verified by comparing simulated
and degradation. Despite this advancement, the current result with historical result from marine lubricating oil
approaches face limitations, such as relying on time company. Multiple data points at various running hours
intervals or reactive interventions, lacking real time will be selected for comparison and will be plotted against
monitoring. Moreover, while the oil analysis methods are actual measured values to assess model’s accuracy.
well-established, the integration into real time monitoring
lubrication oil degradation remains unexplored. To address Verification of BN Depletion
this gap, this study aims to develop a lubricating oil The depletion of Base Number over a period will be
degradation model to aid in the further development of verified by comparing simulated result with historical
lubricating oil real time monitoring to enhance operational result from marine lubricating oil company.
efficiency, reduce cost, downtime and extend engine
lifespan. Verification of Iron Content
4. Methodology The model predict the iron content accumulated in the
lubricating oil sample from Scavenge Drain Analysis. The
iron content will be compared with the actual initial value
to determine the wear rate of the cylinder liner.

5. Conclusion
To conclude this interim report on the development of
lubricating oil degradation model. The proposed model
uses OCTAVE software and science principles, show
Fig. 5 This is an overview of the promising to enhance marine engine health monitoring. By
Project Methodology Road Map focusing on key indicators such as Iron, Base number and
viscosity changes, the model is able to provide early
warning and intervention of potential engine fault.

The shift from traditional planned maintenance to data-

driven condition-based monitoring is a testament of
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advancement in marine engine maintenance strategies. By 4. ISO. (2016). Petroleum, petrochemical and
utilising real-time sensor and data analytic, it offers more natural gas industries — Collection and
accurate and timely assessment of the engine health as exchange of reliability and maintenance data for
compared to conventional method. equipment [Report]. In ISO 14224 (Third
edition). International Organization for
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potential to further improve predictive capabilities and
optimise maintenance schedules and reduce OPEX. This 5. Vo Trong, C., Dai Hoc Binh Duong, Vo, A. D.,
aligns with the industry’s move towards Industry 4.0, HMI Engineering, Doan, M. T., Ho Chi Minh
promising to improve operational efficiency and cost City University of Technology (HCMUT), Vu
effectiveness. Ngoc Bich, & Members, I. (2011).
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