Natural Gas Engine

Oils –
Technical Trends and Updates

Verghese PF
PLS , IEO & Splts

Sentul , 05/10/2017

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Content

• Natural Gas Market update –

– Global and Asia Pacifica NG market Trends
• Natural Gas Engine Oil Technical Update –
– OEM and Engine Trends
– NGEO Lubricant and Additive update
• Overview of Oronite Natural Gas Engine oil Products
• Summary
• Appendix

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Gas Engine Market Trends

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Gas Engine Market Trends

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Gas Engine Market Trends

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Indonesia

• Large proven gas reserve

• Electrification rate still low
– Plan to increase to 90% by 2020
• Demand > Supply
– Due to rapid economic growth and urbanisation
• Gas engine power plant is one of the options for PPU and IPP

• Indonesia is also major coal producer

– Large CBM reserves
• estimated at 4X proven gas reserves

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NGEO - OEM and Engine
Trends and update

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Various Natural Gas Applications
From the Wellhead to End User
Application Typical Natural Gas Engine Type
Wellhead Gathering 4-cycles with some 2-cycles
Gas Processing Plants Large 2-cycles / large 4-cycles
Gas Pipelines / Compressor Stations Large 2-cycles / large 4-cycles / Turbines
Residential Electric Power Plants Large 4-cycles / Turbines
Industrial Electric Power Plants Large 4-cycles / Turbines
Natural Gas Vehicles Mobile CNG / LNG engines

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Natural Gas Engines
Various OEMs, Various Applications

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NGEO OEM update

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NGEO OEM Update

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Key OEM Power Ranges

CAT, Waukesha, GEJ Engines mainly in 500-4000 KW – Small to Medium Range

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Key OEM Power Ranges

Wartsila, MAN Engines mainly in 5000-70000 KW: High HP / Big Engines

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OEM Update – Caterpillar, MWM

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Lubricant Approval Process

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OEM Update - GE-Jenbacher

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Lubricant Approval Process

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OEM Update – Wartsila

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Lubricant Approval Process

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OEM and Market Update

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NGEO Technical Update
Additive , Lubricants

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Natural Gas Engine Oils
What’s Special?

• Gas Engines are used in a variety of Industrial Applications

– High Load Factor …… Severe Oil Stress

– Remote Operations ………Reliability Essential

– Wide Variation in Engines Types …….Flexible Products Required

• There Are No Industry Oil Specifications

– Oils must demonstrate performance in field testing

– Oils must be compatible with engine catalyst

– Oil and Additive Company Expertise is Required

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Various Gaseous Fuels
Various Engine Oils Required
• Propane Fuels
– Typically known as HD-5 Propane but others special duty mixtures exist
– ≥ 95% propane, remaining is a mixture of butane, pentane, and hexane
– LHV (2,300-2,400 btu/cu-ft) – highest maintenance cost
• Natural Gas (Original State)
– Typically known as Field Gas, Wellhead Gas or Wet Gas (can be Sour Gas)
– Various mixtures of methane, ethane, propane, butane, pentane, and hexane
– Hydrocarbons and water may also exist (even with preventative measures)
– LHV (930-2,300 btu/cu-ft) – high maintenance cost
• Natural Gas (Processed)
– Typically known as Dry Gas
– Various mixtures of methane, ethane, propane, butane and trace elements of heavier hydrocarbons – less
than 10 PPM of sulfur compounds (primarily Hydrogen Sulfide)
– LHV (900-930 btu/cu-ft) – lowest maintenance cost
• Bio-Gasses (Sour Gas) – Organic decompositions but they very different
– 35-60% methane, remainder carbon dioxide and other trace elements, >10 PPM of sulfur compounds
(primarily Hydrogen Sulfide)
– Landfill Gas usually contains other harmful elements such as chlorine, fluorine, silica particles and saturated
water vapor while Digester Gas (Bio-mass) does not
– LHV (< 900 btu/cu-ft) – high maintenance cost

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Natural Gas Engines
What NGEOs Must Deliver (4-Cycle)
• Detergents are needed for piston deposit control
– Contribute ash and combustion chamber deposits
• Oil ash needed for valve recession control
– Must be limited to prevent valve problems
• Strong oxidation/nitration resistance for long oil life
– Typically requires ashless inhibitors
• Base (reserve alkalinity) needed to control acid build-up
– Contributes ash
• ZDTP limited to meet catalyst compatibility
– Typical phosphorus maximum is 300 ppm
• Typically need low ash, SAE 40 engine oils
– Caterpillar, Cooper, Superior 1700/2400: 0.4-0.6% sulfated ash
– Deutz, Cummins, Jenbacher: 0.5% max
– Waukesha: 0.35 – 1.0%, model specific
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Natural Gas Engine Oils
Ash Balance is Important

Too Little Sulfated Ash Too Much Sulfated Ash

• Valve Face / Seat Wear  Combustion Deposits
• Short Oil Life Duration • Ash Pounding
– Base Number Retention
• Pre-Ignition / Detonation
– Acid Neutralization
• Valve Torching
– Other
• Compression Loss
• Oxidation / Nitration
 Piston Ring / Liner Wear
• Viscosity Increase
• Piston Land Deposits
• Sludge Formation
• Piston Groove Deposits
 Catalyst Fouling

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Natural Gas Engine Oils
Ash Importance – Valve Wear Protection

Valve Lubrication, Temperature and Cooling

Coolant

Intake Valve Exhaust Valve

Fuel/air & oil cooled Cooled by contact area

Wet Lubrication Protection Dry Lubrication Protection

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 Reduced Crevice Volume For Low Emissions

Traditional Design Low Emissions Design

High Volume Low Volume

Crevice Volume

Liner Liner
Top Compression Top Compression
Piston Ring Piston Ring
Low Emissions Design Places Greater Demands On Engine Oil
• Higher top ring and land temperatures

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Gas Engine Additive and Oil
Technology Trends

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 Summary

– Modern Gas Engine Oil and Additive Technologies Must Meet Increasing Performance Demands:

• Higher BMEP, Higher Temperatures, Lean Burn, Catalysts, Lower Oil Consumption

• Longer Oil Drain Intervals with Improved Deposit Control, Wear Performance.

• Strive to deliver Lower Maintenance and Operating Costs.

– Lubricant Specifications Provide Physical and Chemical Property Guidance but Approvals are
Based on Demonstrated Field Performance.

– To meet the Current and Future Lubricant Needs of Natural Gas Engines and Markets, Oronite is
Continuously Developing Newer Additive Technologies and Products Through a Dedicated Team,
Proprietary Development Tools and Extensive Field Testing.

– OLOA 44507 is Oronite’s New Top Tier Technology with Extended Drain Capability.

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Appendix

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Indonesia

• PLN has a target to increase power by 35,000 MW to support economic growth

and electrification target
– 10,000 MW by PLN
– 25,000 MW by IPP
– Electrification of 84% in 2015 and 99.4% in 2024
• Gas Engine plants (PLTMG) comprises close to 1,500 MW

• In 2013
– GEPP = 0.4% of 46,420 MW
– (Gas Engine Power Plant)

Source: Ministry of Energy and Mineral Resources 2013

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Key OEM Approval Summary

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Caterpillar – Lubricants
Current Lubricant Spec
• SEBU 6400-05, November 2010. “Caterpillar Gas Engine Lubricant, Fuel, and Coolant
Recommendations”
– Defines various fuel qualities
– Minimal changes to the document from the prior issued
– Defines requirements for Field Evaluations
• > 7,000 hour test
• Load Factor – high loads are preferred
• Oil Analysis – Sample at 250 hour intervals and analyze for oil condition and wear metals
• Evaluation Criteria
– Deposit assessments
– Wear measurements
– Oil Life
– G3500 field evaluation
• reads down to G3300/3400 Series
• does not read up to G3600 series
– G3600 series requires separate field evaluation

• Oil Drain Intervals

– CAT recommends that oil be drained based on condition when condemning limits are reached
– Sample used oil at 250 hour increments and analyze for oil condition and wear metals

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 Waukesha – Lubricant Specs

Current Lubricant Specs:

• Service Bulletin 12-1880AG, July 2011- “Waukesha Lube Oil Recommendations”
• Issues Approvals for :
• Oils for Co-Gen Applications - Must have demonstrate satisfactory performance in 4,000
hour field demonstration with jacket water temperatures between 100C and 129C with 500
hr oil drain intervals.
• Oils for Four Series VHP stoichiometric engine in compression (Gas Gathering and
Transmission) service - L3524GSI type Engine, High load for a full year (7,000 hours
minimum).

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Indonesia

• Net exporter of natural gas and coal

– world's 8th largest exporter of natural gas in 2011
– Consumption growing, ~19% of total energy consumption (just behind coal)
– Proved reserves ~141 Tcf conventional
• CBM reserves of ~453 Tcf
• Shale oil and gas potential under study
– Biomass and Renewables make up 29% of primary energy consumption

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China Energy

• Worlds –
• Most populous country
• Largest energy consumer
• Largest coal producer and consumer
• Largest potential shale gas resources

• Unconventional Gas
• Conventional reserves estimated at ~107 Tcf
• CBM technically recoverable reserve estimate, ~350 Tcf
• Shale technically recoverable reserve estimate, ~1,275 Tcf

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Thailand

• Net Importer of Natural Gas

– Natural Gas is ~31% of total energy consumption
– Power generation sector main consumer
– NG vehicle use growing, currently ~5% of total gas demand
– Well developed NG pipeline distribution network
– Pipeline and LNG import facilities

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 Gas Engine Oil Categories

Typical
Sulfated Ash, wt %
(D 874) Application

Ashless < 0.15 2-Cycle

Low Ash 0.15-0.6 4-Cycle

Mid Ash 0.6-1.0 4-Cycle

and Sour Gas

High Ash > 1.0 Severe Fuels

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 Natural Gas Engine Oil Ash and Performance
Requirements (Sweet Gas, Spark Ignited)

Ash, Wt API Listed

Builder Field Test
% Category Approvals
Caterpillar 0.4 - 0.6 Yes No
Jenbacher Stoich <0.5 CC Yes Yes
Leanox 0.6 - 1.0 CD Yes Yes
M.A.N. DE 0.4 – 0.7 --- Yes Yes
Deutz-MWM New <0.5 CC Yes Yes
Old <0.75
Wärtsilä 0.3 - 0.6 --- Yes Yes
Waukesha Model 0.35 - CD Yes *Yes
*Landfill (LFG) & Specific 1.0
Co-gen

Cummins <0.6 --- Yes Yes

Dresser-Rand Cat I, II, --- Yes Yes
III

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Oil Specifications - 1
SO4 Ash, Phosphorus, Zinc, TBN (D 2896),
OEM SAE Grade Other
Wt % Wt % Wt % mg KOH/g
Caterpillar Inc.
Caterpillar (1) 0.4 to 0.6 - - - SAE 30, 40 7000 hr. field test recommended SAE 40 only in Cat
3600
Perkins 4000 Series With Catalyst 0.5 Max. 0.09 Max. 0.04 Max. - SAE 30 or 40 (2)
0.5 to 1.1 LFG Approx 8
Without Catalyst - - SAE 30 or 40 (2)
0.5 Nominal NG 5 to 7 NG
Cooper Bessemer bmep <175 psi 0.4 - 0.6 - with ZnDTP - SAE 40 API CF
bmep >175 psi 0.4 - 0.6 - " - SAE 40 API CF
Dresser Rand Low Ash or Ashless - - - 8.8 cSt - 13.8 cSt @ Field Test/Approval List
99C (SAE 30)
Jenbacher API CC or MIL-L-2104B (CRC L-38 Pass)
Lambda-1, Series 6, <0.5 0.08 Max. - > 3.0, prefer > 4 SAE 40 Field Test/Approval List
Leanox Series 1,2,3,4 requiring Low Ash
MIL-L-2104C Pref./B Accept/(L-38 Pass)
Leanox Series 1,2,3,4 0.6 - 1.0 - - ~8.0 SAE 40 Field Test/Approval List
MAN B&W
MAN B&W Dual Fuel 1.0 Max. 4 to 6 SAE 40 MIL-L-2104D/API CD, Mineral base oil
Field Test/Approval List
MAN Brons 0.35-0.65 Sweet - - 3-6 Sweet SAE 40
0.6-0.9 Sour 5-8 Sour
0.5 Max. Catalyst
Mirlees Blackstone Dual Fuel 1.0 Max. - - Min. 5 SAE 40 API CD/Good Performance List
Ruston Spark Ignition Max.: 0.5 Sweet, Max.: 0.1 Sweet, Max.: 0.1 Sweet, Min.: N/A Sweet, SAE 40 Pref./ Field Test/Approval List
0.7 Sour, 1.0 LFG 0.05 Sour,0.03 LFG 0.05 Sour,0.03 LFG 5 Sour, 8 LFG SAE 30 Accept.
Dual Fuel Max.: 0.7 Sweet, Max.: 0.08 Sweet, Max.: 0.08 Sweet, Min.: 4 Sweet, SAE 40 Pref./
0.9 Sour, 1.0 LFG 0.05 Sour,0.03 LFG 0.05 Sour,0.03 LFG 6 Sour,9 LFG SAE 30 Accept.

MAN Nutzfahrzeuge Spark Ignition 0.4 - 0.7 0.03 % min. 0.03 % min 5 min. Single Grades MAN 3271-2
Special gases - 1.0 (Special Gases - 7 Multi-grades HTHS - 3.5 min.
% max. min.)
MDE Dezentrale Energiesysteme 0.4 - 0.9, none - >3.0 SAE 30/40/20W-40 MAN 3271 Elastomer Test
lower pref. 15W-40/5W-30 Field Test/Approval List

MTU Friedrichshafen 0.6 Max. - Min. 0.02 Min. 4 SAE 40 MTU Elastomer Compatibility (DIN 53521)
FZG Damage Min.11
API CD Min. (CRC-L38 Pass)/Field Test
Updated by L. Copeland - 3/28/03 1 Also Recommend Ashless Oils With Good Field Experience in GXXX Engines
2 SAE 30 below 30°C ambient and 40 above. Multigrades not allowed.
* Jenbacher allows the use of Low Ash Gas Engine Oils in all their engines

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Oil Specifications - 2
SO4 Ash, Phosphorus, Zinc, TBN (D 2896),
OEM SAE Grade Other
Wt % Wt % Wt % mg KOH/g
Deutz - -
Gases (low pollutants) 0.5 Max.
- - 4.5 Min. SAE 40 Field Test/Approval List
Special gases (increased pollutants) 1.0 max
- -
Cummins CNG L10G, QSK19G, QSK45G, QSK60G 0.5 Max. .025 - .035 .025 - .035 5.0 Min. 15W-40 Field Test
B Series, C Series 0.5 Max. .025 - .035 .025 - .035 5.0 Min. 15W-40 Laboratory Engine Test
Cumnmins Stationary QSK 81G, QSK 91G 0.5 Max. .025 - .035 .025 - .035 5.0 Min. 40 Field Test
Cummins DF (Westport Engine) API CI-4 or API CH-4 in NA
15W-40
Global DHD-1 or ACEA E-5 ex. NA
Niigata Dual Fuel 0.9 Max. - - 4 to 7 SAE 30/SAE 40 ISOT/KHT/4Ball, APICD, Field Test
Spark Ignition 0.6 Max. - - 3 to 7 SAE 30/SAE 40 ISOT/KHT/4Ball, APICD, Field Test
Rolls Royce (ex Ulstein Bergen) ≤0.5 NG, <1 biogas
none - ~5 NG, ~7-8 biogas SAE 40 3000 hr. Field Test/Approval List
lower preferred
SEMT Pielstick 0.4 to 0.6 recommended - - - -
Superior
Naturally Aspirated 0.5 to 1.0 Preferred. - - 2 Min. Sweet, SAE 40 CD-II SF Mil-L-2104E No Bright Stock
(Ashless and low ash 6-12 Sour 100% Solvent refined base stocks
acceptable)
Turbocharged 0.5 to 1.0 - - 2 Min. Sweet, SAE 40 CD-II SF Mil-L-2104E No Bright Stock,
(Ashless and low ash not 6-12 Sour 100% Solvent refined base stocks
acceptable)
1700 and 2400 series 0.4 to 0.6 required - - 2 Min. Sweet, SAE 30, SAE 40 API CD w mineral base stocks
6-12 Sour
Wärtsilä
Wärtsilä (SACM) Dual Fuel 1.0 Max. - - 7.5 Min. SAE 40 Pref./SAE 30
Wärtsilä W34SG 0.6 Max. - - 4-7 Accept.
SAE 40 VI 95 Min., only virgin base stocks, 10 %
(Multigrade allowed for Bright Stock max.,
W220SG) Foam Seq. 1/2/3 - 100/0 Max.
Waukesha Field Test/Cogen Approval List
VGF F18,H24,L36,P48 G,GL,GLD 0.45 to 0.75 - 0.1 - SAE 30 or 40 (1)
VGF F18,H24,L36,P48 GSID 0.35 to 0.5 - 0.1 - SAE 30 or 40 (1)
VSG F11 G,GSI,GSID 0.35 to 1.0 - 0.1 - SAE 30 or 40 (1)
VHP 2895,3521,5790,7042,9390 G,GSI,GSL 0.35 - 1.0 - 0.1 - SAE 30 or 40 (1) mineral or synthetic base
VHP 3524,5794,7044 GSI; 5774,5794 LT 0.45 to 0.75 - 0.1 - SAE 30 or 40 (1) permitted
AT 25/27,8L,12V,16V GL 0.35 to 1.0 - 0.1 - SAE 30 or 40 (1)
Updated by A. Beckman - 11/27/07 1 SAE 30 below 71°C sump and 40 above

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 Oil Specifications – 3

Ash Category Ash Level

Zinc (4)
Low API
Builder Ashless Min. Max. Max., Comments Viscosity V.I. Base Stocks
Ash Service
%
(2) 12.5 cSt -
Cooper-Bessemer
bmep <85 psi X X Nil 0.6 Ashless Pref. CC 16.3 cSt @ 70 Min. No Bright Stock
bmep >85 psi X Nil 0.8 Ashless Pref. CC 100C
Dresser-Rand (Clark) X X Port Plugging 11.3-13.8cSt Carbon Residue -
Minimized With at 100°C 0.15 % max. of
Ashless base oil
Dresser-Rand No Ash MIL-L-2104(CB) SAE 40 HVI or MVI
(Worthington) Recommendations
Fairbanks Morse,
Dual Fuel X 0.4 1.0 3-10 TBN MIL-L- SAE 30 or 55 to (5)
Naphthenic
Spark Ignition X 0.2 0.5 3-7 TBN 2104B(CC) (1) 75
SAE 40
(2) X X 0 0.8 0.04 Ashless Pref. CC (3) 70 Min. No Bright Stock
Ajax SAE 30
Updated by L. Copeland - 1/20/03 1 SAE 30 for Oil Temperature <185°F; SAE 40 for Oil Temperature >185°F
2 Manufactured by Cooper Energy Services
3 15W-40 Multigrades Acceptable if Required for Cold Start
4 Most Builders Weigh Field Performance More Heavily than API Classification
5 Paraffinic Base Oil Also Acceptable With Good Performance

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 Used Oil Guidelines
Used Oil Condemning Limits

KV at 40°C, KV at 100°C, **BN (D 2896), TAN (D 664), DIR Oxidation, DIR Nitration,
OEM pH
(mm2/s) (mm2/s) mg KOH/g mg KOH/g (abs/cm) (abs/cm)
Caterpillar Inc.
Caterpillar 3 mm2/s increase 50% decrease 3 mg KOH/g max. 25 max. 25 max.
2 mgKOH/g increase
Dorman 8 mm2/s increase 25% increase 50% decrease 2.5 mg KOH/g increase - 25 max. 25 max.
Perkins 4000 Series NG - 16.5 mm2/s 50% decrease < actual BN - 25 max. 25 max.
Biogas - 16.5 mm2/s 50% decrease < actual BN - 30 max. 25 max.
Dresser Rand (4T) - 8.48 mm2/s min. 50% decrease 4 mg KOH/g max. 3 min. 20 max. 20 max.
15.52 mm2/s max.
Jenbacher 25% increase - 50% decrease 80% of BN max. 4.0 min. 20 max. 20 max.
Man B&W
Man B&W Dual Fuel 190 mm2/s max. - 40% decrease 0.15 mg KOH/g SAN max. - 20 max. 20 max.
Ruston 30% increase 30% increase 40% decrease 2.5 mg KOH/g max. - 20 max. 15 max.
MDE Dezentrale Energiesysteme 1 SAE grade 40% 1 SAE grade 70% decrease - 5 min. 20-30 max. 20-30 max.
increase
Deutz* - 12 mm2/s min. 40% decrease ? actual BN 4.5 min. (1) 20 max. 20 max.
18 mm2/s max. 2 mg KOH/g min. 0 mg KOH/g SAN max.
20% increase max.
Niigata 20% decrease 30% - 1 mg KOH/g min. 2 mg KOH/g increase - - -
increase
Rolls Royce (ex Ulstein Bergen) 25% increase - 50% decrease 2.5 mg KOH/g increase - - -
40 mm2/s min/500 C
for SAE 30
Superior 204 mm2/s max. 12.5 mm2/s min. 2 mg KOH/g min. - - - -
16.3 mm2/s max.
Wärtsilä W34SG 50% increase 25% increase 50% decrease 2.5 mg KOH/g increase n-pentane insol. 25 max. 20 max.
1.0% max
Waukesha 20% decrease *30% of fresh oil* 2.5 - 3 mg KOH/g increase - 25 max. 25 max.
30% increase by D4739
Updated by A. Beckman 11/27/07 1 Deutz method
* Wear Metals limits depend on engine model (see Deutz Technical Circular)

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