CHAPTER 4

DESIGN OF LUBRICATING SYSTEM

4.1 LUBRICATING OIL STORAGE TANK:

Design Parameters:

Type Cylindrical

Installation above the Ground

Capacity 30 day’s supply

Combined number of hours

in operation of four engines 65 hours/day

Volume of sump tank 4.0 m3

Specific Lube Oil Consumption 0.6 g/kW-hr

Brake Power 2850 Kw

4.1.1 Mass Flow Rate of Lubricating Oil Consumption (For One

Engine), mL:
mL =mLB × Pb
Where:
mL= Lube Oil Consumption
mLB= Specific Lube Oil Consumption
Pb = Brake Power
Substituting,
grams
𝑚𝐿 = 0.6 × 2,850 kW
kW-hr
grams
mL = 1710
hr
4.1.2 Density of Lubricating Oil Consumption, VL

1
 𝜌𝐿𝐵
𝑆𝐺 =
𝜌𝐻2𝑂
Where:
SG=0.91 for SAE 40
𝜌𝐿𝐵 = density of lube oil
𝜌𝐻2𝑂 = density of water, 1000kg/m3
𝜌𝐿𝐵 = 𝑆𝐺 × 𝜌𝐻2𝑂
Substituting the values,
𝑘𝑔
𝜌𝐿𝐵 = 0.91 × 1000
𝑚3
𝒌𝒈
𝝆𝑳𝑩 = 𝟗𝟏𝟎
𝒎𝟑
4.1.3 Volume Flow Rate of Lubricating Oil Consumption, VL
𝑉𝐿 = 𝑚𝐿𝐵 × 𝜌𝐿𝐵
Substituting the values,
𝑘𝑔
1.710
ℎ𝑟
𝑉𝐿 = 𝑘𝑔
910 3
𝑚

𝑚3 1000𝑙𝑖 1𝑔𝑎𝑙
𝑉𝐿 = 0.00188 ℎ𝑟 × × 3.785𝑙𝑖
1𝑚3
𝒈𝒂𝒍
𝑽𝑳 = 𝟎. 𝟓 𝒉𝒓

4.1.4 Volume Lubricating Oil Consumption per Month:

Let the Lubricating Oil delivery to be every 3 months
and a contingency of 25% for it not to run dry during the
operation.
gal 65 hours 90 days
VL =0.5 × ×1
hr 1 day month

gal 1 ft3 1 m3
VL = 2925 x x
month 7.482 gal 35.31 ft3

VL = 11.07 m3(per Engine)

Total Volume of Lube Oil Consumption for four (4) engines is
equal to, Vt = 11 × 4 = 44𝒎𝟑
Using two lube oil storage tanks, the capacity per tank would
be equal to 22 𝒎𝟑

2
4.1.5 Dimensions of Cylindrical Lube Oil Storage Tank:
Let the volume of the tank be equal to the volume of
cylinder

VLT = Vc

Assume:

Height of the tank = 1.5 x Diameter of the tank

H = 1.5DT

Thus,

π
Vc = DLT 2 (1.5DLT )
4

Vc = 0.375πDLT 3
Vc
DLT 3 = 0.375π

3 c V
DLT = √0.375π

Substituting,

3 25 m3
DLT = √0.375π

Therefore,

HLT = 1.5(2.80 m)

HLT = 4.20 m

4.1.6 Surface Area of the Cylinder, SAc:

π
SAc = ( 4 D2 )+ π(DH)

Where:

D = diameter of storage tank

H = height of storage tank

3
Therefore,
π
SAc = (2.80 m)2 + π(2.80 m× 4.20 m)
4

SAc = 43 m2

4.2 THICKNESS OF THE STORAGE TANK

From A Textbook of Machine Design by Khurmi and Gupta,

p. 226. The design of a pressure vessel must be based on the

maximum stress.

Therefore,

𝑝×𝑑
𝑡=
4𝜎2 ×𝜂𝑐

Where:

P = Maximum Allowable Internal Pressure

d= Inside Diameter of the storage tank

𝜂𝑐 =efficiency of circumferential joint

𝜎2 =stress value of carbon steel SA-285

4.2.1 Pressure inside the tank, P:

P= δL ×hL

4.2.2 Height of the Lube Oil, hf

4
 hL = 4.20 m

4.2.3 Specific Weight of Lube Oil, δL

𝛾f =SGf x𝛾w

Where:

SGL =0.91

𝑘𝑁
δw =9.81 𝑚3

Substituting the values,

𝑘𝑁
𝛾L =0.91 ×9.81 𝑚3

𝒌𝑵
𝜸L =8.9271 𝒎𝟑

Substituting,
P= δL ×hL
𝑘𝑁
PS = (8.9271 𝑚3 × 4.20m)
PS = 37.50 kPa
PS = 5.44 psi
Therefore,
Pa =Ps +Patm
Pa = 5.44 psi + 14.7 psi
Pa = 20.14 psi
4.2.4 Maximum Allowable Working Stress, S

Table 4. Design Equation Data for Pressure Vessel

Recommended Stress Values
Metal Temperature, F S, Psi

Carbon Steel (SA-285, Gr. C) -20 to 650 13,700

From Peters, M.S. and Timmerhaus, K.D. 1991. Plant Design

and Economics for Chemical Engineers 4th ed. New York; McGraw,
Inc.
5
4.2.5 Welding Efficiency, EJ

From PME Code; p. 147; the efficiency of doubled

butt weld for fusion weldjoints is 70%.
Therefore,

𝑝×𝑑
𝑡=
4𝜎2 ×𝜂𝑐

Substituting the values,

lb 3.281 ft 12 in
(20.14 2 )(2.80m)( )( )
in 1 m 1 ft
tST = lb
4(13700 )(0.70)
in2

tST = 0.058 in

tST =1.47 mm

From PME Code, 2012 Edition, Page 418.

Table 2215.2.1.7 Shell Plate Thickness

Nominal Tank Diameter Nominal Thickness

m Ft mm in

< 15 <50 5 3/16

15 to <36 50 to <120 6 1/4

36 to 60 120 to 200 8 5/16

>60 >200 10 3/8

For lube oil tank, standardized values from the PME code, for
diameter less than 15 meters, use data as specified.

Therefore,

tST = 5.0 mm

6
Specification of Lube Oil Storage Tank

Type of material used Carbon Steel (SA – 285,Gr.C)

Height of the storage tank 4.20 m

Diameter of the storage tank 2.80 m

Thickness of Storage Tank 5.0 mm

4.3 PIPING DESIGN AND SELECTION

4.3.1 Pipelines from Storage Tank to Engine

Volume of Storage Tank 22 m3

Filling Time 15 minutes

From Power Plant Engineering by Morse, page. 603.

The parameters to be used in the determination of appropriate

specification for pipelines suited for this kind of
application are; the assumed filling time which is 15 minutes
and the average velocities at pump’s suction and discharge
line which are 106.5 and 137 m/min respectively.

4.3.2 Volume Flow Rate of Lube Oil from Storage Tank to

Engine, Qs-e:

𝑉𝐷𝑇
Qs-e = 𝑇𝑓

Where:

VST = capacity of day tank

Tf = the assumed filling time

Substituting,

7
 22 m3
Qs-e =
15 min

Qs-e= 1.47 m3/min

4.3.3 Diameter of Pipe at Suction Line, Ds:

𝜋𝐷𝑠 2 𝑉𝑠
𝑄𝑠−𝑒 =
4

4𝑄𝑠−𝑒
𝐷𝑠 2 =
𝜋𝑉𝑠

4𝑄𝑠−𝑒
𝐷𝑠 = √
𝜋𝑉𝑠

Where:

Qs-d = volume flow rate of lube oil from

storage tank to day tank

Vs = velocity of lube oil at suction line

Substituting the values:

3
4 (1.47 m ⁄min)
Ds = √
π(106.5 m⁄min)

Ds = 0.133 m or 133 mm

Say use 150 mm

Thus,

From TABLE E2.1 Principal Properties of Commercial Pipe page

2257 of PIPING HANDBOOK by Mohinder L. Nayyar

8
 Nominal Schedule Outside Wall Inside
Diameter,mm Number Diameter Thickness(mm) Diameter(mm)

150 Std. 40 168.275 7.112 154.051

4.3.4 Diameter of Pipe at discharge line, Dd:

𝜋𝐷𝑑 2 𝑉𝑑
𝑄𝑠−𝑒 =
4

4𝑄𝑠−𝑒
𝐷𝑑 2 =
𝜋𝑉𝑑

4𝑄𝑠−𝑒
𝐷𝑑 = √
𝜋𝑉𝑑

Where:

Qs-d = volume flow rate of lube from

storage tank to engine
Vd = velocity of lube oil at discharge line
Substituting,

3
4 (1.47 m ⁄min)
Dd = √
π(137 m⁄min)

Ds = 116.88 mm

Say use 125 mm

Thus,
9
From TABLE E2.1 Principal Properties of Commercial Pipe page
2257 of PIPING HANDBOOK by Mohinder L. Nayyar

Nominal Schedule Outside Wall Inside

Diameter, Number Diameter Thickness(mm) Diameter(mm)

(mm)

125 Std. 40 141.3 6.553 128.94

10
Pump System
Solving for Pump from Storage to Engine

1. FOR DYNAMIC DISCHARGE HEAD

A. Solving for the total dynamic head of lube oil, TDH:

TDH = DDH – DSH →working equation.

Where:

DDH = dynamic discharge head at the pump’s discharge side.

DSH = dynamic suction head at the pump’s suction side.

For DDH:

11
 𝑃𝐷 𝑉𝐷 2
DDH = + + 𝑍𝐷 +𝐻𝑓𝐷
𝑌𝐹 2𝑔

Where:

PD = pressure at the discharge side, 222.825 kPa

ZD = static head at the discharge side, 0.796 m

𝐻𝑓𝐷 = friction head/loss at the discharge side

B. Solving for the velocity of liquid inside the pipe:

Q = AV → Continuity equation.

V = Q / A
𝑚3
1.47
V = 𝜋
𝑚𝑖𝑛
(0.12894 𝑚)2
4

V = 112.58 m / min

V = 1.88 m/sec

C. Solving for the friction head at discharge side, 𝑯𝒇𝑫

𝐻𝑓𝐷 = 2fLV2 / gD

Where:

𝐻𝑓𝐷 = friction head / loss , m of fluid

f = friction coefficient of pipe.

12
 L = total straight length of pipe, m

V= velocity of liquid, m/sec

g = acceleration due to gravity, 9.81 m/sec2

D = inside diameter of pipe, m

D. For coefficient of friction, f:

f = 0.0035 + 0.0007562 (z / DVS)0.424 → for Iron and Steel

Where:

z = viscosity, centipoises

D = inside diameter of pipe, m

V = velocity of liquid, m/sec

S = SG of liquid = 0.91

For absolute viscosity, z:

Lube oil is consumed at 25˚C

From PPE by Morse, page 606.

Temperature (˚C) Lube Oil (Centipoises)

21.1 200

25 Z

26.7 100

By Interpolation:

z = 130.36 centipoises

For identifying the flow characteristic of liquid inside the

pipe:

13
  (z / DVS) < 1163.5 → flow of liquid is
turbulent in clean pipe.

 (z / DVS) > 1163.5 → flow of liquid is

laminar in all pipes.
130.6
𝑧 / 𝐷𝑉𝑆 =
0.12894(1.88)(0.91)

z / DVS = 592.05

Therefore, the flow of liquid inside the tank is

turbulent.

Therefore,

f = 0.0035 + 0.0007562 (592.05)0.424

f = 0.015

E. Solving for the total length of straight of pipe, L:

 Valves and Fittings used in the discharge side are as

follow:
 1 Gate valve
 6 (90° Standard elbow)
 4 Standard Tee

From Table 7.4 Equivalent lengths in straight pipe of

several fittings, meters, from RAC by Stoecker and Jones,
page 139, we can get the equivalent length of straight pipe
of these fittings.

L = LS +LE

Where:

LS= straight length of pipe, meters

LE = equivalent length of all fittings, meters

F. Equivalent length of straight pipe of fitting:

14
 For nominal diameter (DN) of standard pipe of 250 mm,

From TABLE C17.6 Equivalent Lengths for Various Sizes of

Valves and Fittings page C.850 of PIPING HANDBOOK by Mohinder
L. Nayyar

90° Standard Elbow = 3.7 m

Standard Tee = 1.07 m

From TABLE C9.10aM (SI) Valve Losses in Equivalent

Meters of Pipe page C.493 of PIPING HANDBOOK by Mohinder L.
Nayyar

Gate Valve = 1.4 meters

Length of Straight pipe (from drawing) = 34.5 m

For Gate valve: (Assume to be fully open)

L = 40.1 m +[(1)(0.0 m)+(11)(0.9 m)+(1)(36.6 m)]

L = 86.6 m

G. Solving for the friction head at discharge side, 𝑯𝒇𝑫

𝐻𝑓𝐷 = 2fLV2 / gD

𝐻𝑓𝐷 = (2 x 0.017 x 86.6 x 1.462) / (9.81 x 0.10226)

𝐻𝑓𝐷 = 6.25 m

𝑽𝑫 𝟐
H. For the velocity head at discharge side, 𝟐𝒈

𝑉𝐷 2
HV = 2𝑔

(1.442 𝑚⁄𝑠𝑒𝑐 )2
𝐻𝑣 =
2𝑥 9.81𝑚/𝑠𝑒𝑐 2

15
 HV = 0.106 m

I. Solving for the Dynamic Discharge head, DDH:

Note:

ZD = 3.48 m

𝑃𝐷 𝑉 2
DDH = + 2𝑔𝐷 + 𝑍𝐷 + 𝐻𝑓𝐷
𝑌𝐹

222.825 𝑘𝑃𝐴
𝐷𝐷𝐻 = ( + 0.11 + 3.48 + 6.25) 𝑚
9.81 𝑘𝑁⁄𝑚3

DDH = 32.55 meters

2. FOR DYNAMIC SUCTION HEAD

A. Solving for the Dynamic Suction Head, DSH:

𝑃𝑆 𝑉𝐷 2
DSH = + + 𝑍𝑆 - 𝐻𝑓𝑆
𝑌𝐹 2𝑔

Where:

PS = pressure at the suction side = 228.845 kPa

16
 ZS = static head at the suction side = 0.3305 m

𝐻𝑓𝑆 = friction head or loss at the suction side

B. Solving for the velocity of liquid inside the pipe:

Q = AV → Continuity equation.

V = Q / A
𝑚3
1.47
V = 𝜋
𝑚𝑖𝑛
(0.154051 𝑚)2
4

V = 78.87 m / min

V = 1.3145 m/sec

C. Solving for the friction head at discharge side, 𝑯𝒇𝑫

𝐻𝑓𝐷 = 2fLV2 / gD

Where:

𝐻𝑓𝐷 = friction head / loss , m of fluid

f = friction coefficient of pipe.

L = total straight length of pipe, m

V= velocity of liquid, m/sec

g = acceleration due to gravity, 9.81 m/sec2

D = inside diameter of pipe, m

D. For coefficient of friction, f:

f = 0.0035 + 0.0007562 (z / DVS)0.424 → for Iron and Steel

Where:

z = viscosity, centipoises

D = inside diameter of pipe, m

V = velocity of liquid, m/sec

17
 S = SG of liquid = 0.91

For absolute viscosity, z:

Lube oil is consumed at 25˚C

From PPE by Morse, page 606.

Temperature (˚C) Lube Oil (Centipoises)

21.1 200

25 Z

26.7 100

By Interpolation:

z = 130.36 centipoises

For identifying the flow characteristic of liquid inside the

pipe:

 (z / DVS) < 1163.5 → flow of liquid is

turbulent in clean pipe.

 (z / DVS) > 1163.5 → flow of liquid is

laminar in all pipes.
130.6
𝑧 / 𝐷𝑉𝑆 =
0.154051(1.3145)(0.91)

z / DVS = 708.72

Therefore, the flow of liquid inside the tank is

turbulent.

18
Therefore,

f = 0.0035 + 0.0007562 (708.72)0.424

f = 0.0157

E. Solving for the total length of straight of pipe, L:

 Valves and Fittings used in the discharge side are as

follow:
 1 Gate valve
 2 (90° Standard elbow)
From Table 7.4 Equivalent lengths in straight pipe of
several fittings, meters, from RAC by Stoecker and Jones,
page 139, we can get the equivalent length of straight pipe
of these fittings.

L = LS +LE

Where:

LS= straight length of pipe, meters

LE = equivalent length of all fittings, meters

F. Equivalent length of straight pipe of fitting:

For nominal diameter (DN) of standard pipe of 150 mm,

we have,

Gate Valve (fully open) = 2.10 m

90° Standard Elbow = 3.66 m

Length of Straight pipe (from drawing) = 2.5051 m

For Gate valve: (Assume to be fully open)

19
 L = 2.5051 m +[(1)(2.10 m)+(2)(3.66 m)]

L = 11.9251 m

G. Solving for the friction head at suction side, 𝑯𝒇𝑫

𝐻𝑓𝐷 = 2fLV2 / gD

𝐻𝑓𝐷 = (2 x 0.0157 x 11.9251 x 1.31452) / (9.81 x 0.154051)

𝐻𝑓𝐷 = 0.4281 m

𝑽𝑫 𝟐
H. For the velocity head at discharge side, 𝟐𝒈

𝑉𝐷 2
HV = 2𝑔

(1.442 𝑚⁄𝑠𝑒𝑐 )2
𝐻𝑣 =
2𝑥 9.81𝑚/𝑠𝑒𝑐 2

HV = 0.106 m

I. Solving now for the Dynamic Discharge head, DDH:

Note:

ZD = 3.48 m

𝑃𝐷 𝑉 2
DDH = + 2𝑔𝐷 + 𝑍𝐷 + 𝐻𝑓𝐷
𝑌𝐹

222.825 𝑘𝑃𝐴
𝐷𝐷𝐻 = ( + 0.11 + 3.48 + 6.25) 𝑚
9.81 𝑘𝑁⁄𝑚3

DDH = 32.55 meters

3. Solving for the Total Dynamic Head, TDH:

TDH = DDH - DSH

TDH = 32.55 m – 25.6 m

20
TDH = 6.95 meters

4. Solving for the rated horsepower of pump to be used, HP:

HP = (Q x TDH x 𝛾F) / pump effy.

Where:

HP = net positive suction head available

Q = flow rate of fuel.

𝛾F = specific weight of fuel

For pump efficiency: (Assume pump efficiency of 80%)

Therefore,

Pump effy. = 80%

3 1 𝑚𝑖𝑛
[0.722 𝑚 ⁄𝑚𝑖𝑛 (60 𝑠𝑒𝑐 ) ] (6.95 m) (9.81 𝑘𝑁⁄𝑚3 )
HP=
(0.80)

1 𝐻𝑃
HP=( 1.03kW) ( )
0.746 𝑘𝑊
HP = 1.37 horsepower

For Standard Pump size,

Use, 1.5 Hp

21