(ODI) for Diesel Engines
Contents
1. Calibration as a Solution Method Fuel Econ vs Ave Speed Calibration Map ODI Estimations 10 20 30 40 50 Note This is only an example not based of tests _ _ ___ niet 7 pu u f Noria s 13th Annual Conference amp Exhibition E qa GRELABLEPLANT S OLA NA LOUIS DJ MAY T2 A m a Calibration as a Solution Method Possible Algorithms e Three unproven methods to calculating the oil drain interval Paradise Garage Method Kublin Method tested TEN bie inch fested miles tested miles oi change virgin TAN X10 oil capacity bape oil change virgin TEN horsepower Heidebrecht Method o al oil virgin TEN target TEN leviinder bore lx zo cylinders compression ratio lmeutratiza tian Moli Ref oilstudy spacebears com e Simply using the known TBN of the engine oil used at the time of fill the critical TBN limits and the physical characteristics of the engine a decent formula can be created to estimate the oil drain interval time n Il m e a A Iam a dee qutt Noria s 13th Annual Conference amp Exhibitio i a i 2 prt S RELIABLEELAN xe M rae a we Calibration as a Solution Method Onboard Sensors e Onboard sensors can provide significant improvements in determining a proper ODI e Many sensors that could be useful to monitoring the oil condition2. fais bitig Noria s 13th Annual Conference amp Exh SUELUABLEPLANT i i b Mi Er oO 1 a v N Ouick Facts for Class 8 Trucks INDIAN APGLISAIN EV E 2 4 million excluding government and farm in 2008 in the US alone eThere are between 35 58 quarts of oil compared to the 5 7 quarts ina typical car eStandard oil drain interval is 25 000 miles One quart of 15W 40 mineral oil can cost about 3 5 eClass 8 trucks with a trailer average is just under 6 MPG compared to 4 MPG 30 years ago Optimizing the Oil Drain Interval ODI for Diesel Engines Bennett Fitch B S Mechanical Engineering Georgia Institute of Technology Product Development Engineer Navistar Inc gt RUPLA E t 0 TN N INDLANAZOLIS N MA 1 3 A AN M Overview of presentation Historical Perspective Quick Basics How the engine is effected by degraded engine oil How the engine oil becomes degraded Root Cause Root Cause Flow Chart Oil Conditions Driving Conditions Engine Conditions The Answers Oil Analysis Calibration and Algorithms Going Further In Review Acknowledgements M pat Wy ja a s 13th Annual Conferer ne S RELIABEPLANT E NONA 6 ES D o NEY T n etta n Lubrication ona Maintenance Guide Historical Perspective The trucking industry has come a long way Goin
3. 56MPG smPG Diesel DD15 50000 35000 25000 455 560 26 MPG 56MPG k5MPG DD16 50000 35 000 25000 47 475 600p6MPG 56MPG k5MPG Dii upto3500 38 325 405p6MPG gt 4 7MPG p37MPG Volvo D13 upto35000 38 375 500b6MPG p47MPG P37MPG D16 upto35000 44 500550p6MPG gt 4 7MPG p37MPG MP7 35 000 25000 15 000 10000 325 405 gt 6 MPG P47MPG p37MPG p20MPG MP8 35 000 25000 15 000 10000 415 505 gt 6 MPG P47MPG p37MPG p20MPG MP10 50 000 35 000 25 000 15000 515 605 gt 6 MPG P47MPG p37MPG p20MPG PACCAR MX vupto4000 42 380485 31 40 000 30 000 18000 42 330 390p6 5MPG 56 5MPG K5MPG 33 40 000 30 000 18000 42 410 5006 5MPG 5 6 5MPG K5MPG 35 40 000 30 000 18000 42 425 550p6 5MPG 56 5MPG kSMPG NINIK TN N NN N I A SEO NN TN INT N K N NNN NN N A EY NN TT I N NN K N NNN N N N O EA NNN N TN A Driving Conditions Operalions Fuel Econonw IGHT 6 5 MPG or Higher MODERATE 6 5 mpg 5 0 mpg SEVERE LESS THAM 5 0 mpg E N MORE THAM 4 KmpL 3 2 KmpL LESS THAM 2 KmpL Change Engine Oil and Filterf oP 30 000 mi 48 300 km Part 3007498C92 cn Based on a fuel economy of 5 8 m
4. lower viscosity grades are becoming more desirable e With heavy duty engines a better protection against high shear rate is necessary compared to lighter duty vehicles e APICJ 4reguires a minimum high temperature high shear HTHS viscosity of 3 5 cP Too low HTHS viscosity adversely affects protection of bearings and ring cylinder wall contacts Too high HTHS viscosity adversely affects fuel economy Higher average viscosity index assists in maintaining a proper HTHS of 3 5 mPa s for heavy duty vehicles 15W 40 10W 40 10W 30 5W 40 a 200 4 180 Cn e Average VI 2 AE Ma CD SN c c Noria s 13th Annual Conference Fi 1 1 XMibition w a INDIANA POMISNIN EVIA Yai 3 A 3 5 z SAE 20 SAE 30 SAE 40 50 T g 30 3 2 5 25 r 2 0 E o 2 gt 1 5 T o 1 0 0 2 c J g 05 x 00 iL 0 5 13 18 23 28 33 38 43 43 0W30 Viscosity HTHS 150 C 3W40 e SAE 5W 30 Shell Rimula R6 LME has been measured to have a 1 196 lower fuel consumption compared to 10W 30 in a Scania DC9 with a EURO III engine The Answers e When does the cost saved by extending the oil drain interval become insignificant compared to eventual damage costs from extending this interval If the oil could talk it would say e When any oil attributes degrades to it s condemning limit e When the loss of TBN leads to internal
5. Low Temperature Pumpability Additive Solubility Low Cost Detergency fs l ara l fees Oil Conditions M NW E mt d Y Exhibitit 2 AAA Nii 2 q S i g In 42th Annual Canforanr 4 Noria s 13th Annual Conference s or W g 7 EN S et kd onm omin beak nts innon ee INDIANA PODISAIN EIVIA Yai 3 Improved fuel economy e reducing operating costs e This is only correlated with the lower viscosity of synthetics Improved oil pumping on low temperature start up e reducing wear Improved startability e reduced starting times Improved engine cleanliness e resulting in maintenance of engine performance emissions fuel economy etc throughout the oil drain interval Improved soot handling e Prevent sludge formation and oil way blockage in modern emission controlled engines 20 OOS Ref O Oil Conditions INDIANAPBOLISAIN BIVIAY al Longtime Industry Standard i Improvement possibilities with10W 30 or 5W 30 Synthetics ePossible fuel economy improvements as viscosity is decreased eMust meet API CJ4 requirements e5W 30 ambient temperature range no greater than 90 F is disadvantageous Ref flitalia dieselnet com n aN d mii Noria s e amp Exhibitio EUER y de P NINE OLS Ho MEN 12 0 pene a a T A ate AN Impact of Average Viscosity Index on HTHS With increasing pressure to improve today s fuel economy
6. are already in place such as coolant temperature vehicle speed averages fuel consumed engine rpm oil temperatures etc e In addition a sensor dedicated to monitoring the oil condition can be done through Electric capacitance or dielectric loss factor Micromechanical resonator Microacoustic piezoelectric effect AC signals Water and glycol contaminant levels Oil levels NOx levels i W ui a ja mii Noria s 13th Annual Conference amp Exhibition S RELUBLEPLANT INDIANAN ZOU INO MENO 3 a ut mt e iss ay Future Opportunities e API PC 11 Proposed Category 11 for Diesel Engine Oil Anew benchmark for heavy duty diesel engine oil to meet the increasing need to improve fuel economy through a lower viscosity oil solution among other needed changes Creation of two sub categories e Category one for backwards compatibility historical HD oils Maintain a HTHS viscosity of 3 5 mPa s e Category two for fuel economy improvements Allowance of 2 9 mPa s thus having friction reduction Improved protection under higher engine operating temperatures Improved protection against engine oil shear down Increased wear concerns may be addressed with improved piston liner improvements among others Began in June 2011 first license no later than 2016 An LA Uu f Noria s 13th Annual Co
7. corrosive attacks e When sludge begins to build up and lodge itself onto engine components The answer lies with the operators ability to monitor the quality of the oil at any given moment N either by e Oilanalysis e Estimating based on driving routes driving styles environment engine oil in use and the N current condition of the engine 0 24 hibitio wet 2 eM lr fu 2 et i atts aet H Bit Extended ODI Oil Analysis Criteria Oil sample collection methods must follow a proper sampling procedure Consistent intervals at least 10 000 15 000 mile interval is acceptable Thorough records of mph mpg date oil used maintenance logs make up oil volume during interval driving patterns idling time engine history An appropriate and consistent sampling port use An appropriate consistent testing method v i Ja ais et Noria s 13th Annual Conference amp Exhibition 2 ja RELIABLEPLANT 1653 INDIANA POMISNIN BIVIAY al 3 aa a Oil Analysis Guidelines for Cummins Engines QU 4 s w nx GI Cummins Note These contamination guidelines are guidelines only and considered to be loose by many This does not mean values that fall on the acceptable side of these guidelines can be interpreted as indicating the oil is suitable for further service Viscosity change 100 C ASTM D445 1 SAE Viscos
8. ants on the engine oil heat related stressors and the engine oil s overall ability to continue functioning in a positive way When an engine oil loses its alkalinity detergent additive the TBN will drop corrosion risk gt When an engine oil begins to oxidize or become excessively contaminated with glycol or combustion blowby acids its TBN will drop lt o5 wa H 100 150 200 250 300 Oil Eguivalent Hours Il Lai i 2 Nr para CU Ay ja Ex 3th Annual Confer lt SI RELIMBLEPLAI INDIANA hibi a a a Particle Control e Particles produce particles One particle has the power to generate as many as 20 new particles from the time of ingression to when it is finally removed obliterated or settled away After simulating this same potential for these 20 new particles and so on the oil appears to act more like the engine s deathblow then the it s lifeblood e Mass balance The filter is essential in maintaining the ability to remove at least the same number of contaminants that are ingressed in the oil throughout the filter s life If not these contaminants will propagate into a engine wide pandemic and the eventual failure of the engine Di N xhi Um p Latin aN Noria bit wi 0 NI v di s 13th Annual Conference amp ition 1 y 00 RELIABLEPLANT Less NORET IIo MAY I oe Bie ed Eh
9. drop and the eventual engine corrosion Decrease in Viscosity e Soot Can lead to an increase in viscosity and many other issues EEE ee wi I x a Ar N aa J Noria s 13th Annual Conference amp oe E SL RELIABLEPLANT ig s INDIANAPOLIS INo MAY TS oy Pr ae att N Every Engine is a Little Different e Factors among different engines that affect the ODI Age of the engine Miles on engine Engine design e Exhaust gas recirculation e Aftertreatment system e Filter options oil fuel and air Low Fuel High Tail and Oil Pipe Economy Emissions Pretending to Shorter Short rebuild Less work Operating Environmental save money by oil life interval performed costs fuel cost buying cheap material sluggish and oil oil and air and labor slower filters operation leads to i amp Lower eguipment availability gt gt EEE ee e K En Engine Conditions C AEL IABLEPLANT d ee a P M bU N MVA Several commercial filters are available to improve the life of the engine oil One example WIX XD Designed for high capacity and high efficiency e Spin Flow Technology Nylon fins that spin the incoming contaminated oil in a clockwise centrifugal flow to help disperse heavy contaminants tis key to ensure that the filter choice has the dirt holding capacity in line with the oil change interval Make sure filters ar
10. e tested to ISO 4548 12 related to capture efficiency micron rating and dirt holding capacity Good rule of thumb when choosing a filter Quality of filter should correlate with quality of engine oil You get what you pay for 3 K En Engine Conditions C AEL IABLEPLANT 1 ee an P M US MAY e More stringent emissions strategies e Engines with smaller oil capacities increase the concentration of contaminants thus decreasing the ODI 13L 2010 MaxxForce Engine 42 quart capacity Detroit Diesel DD13 42 quart capacity Volvo D13 38 quart capacity Cummins ISX 12 44 quart capacity e Also engines that have difficulty maintaining a proper oil level can increase the concentration of contaminants as well as heat thus causing further damage to the engine Engines with a strong history of failure cannot be reliable candidates for extended oil drain intervals 48 eee 0 n m23a129Vv5senuss lt r Ref Noria Corp P mn Noria s 13th Annual Conference amp Exhibition 2 Ps BELIABLEPLANT i re Major Engine Oil Properties Contributed by Property Base Oil Additives Mineral Synthetic 1 EL 6 w VR G N Viscosity Viscosity temperature IV Shear Stability Anti Wear protection Rust amp Corrosion Protection Oxidation Stability Tai m 4 Low Volatility Negative Effect Thermal Stability
11. g back to 1949 Gulf had an oil drain interval recommendation between 500 and 1000 miles This oil drain interval with vast improvements in truck design and oil formulation has increased to as much as 50 000 miles today Crude oil prices are still driving us to reduce costs wherever possible and improvements can be made as an ac CI a TN Noria s 13th Annual Conference amp Exhibition v eM vBELIABLEPLAMNT ip b in 4 INDIAN 205 IW o MNT SS MM The Factors that Induce Engine Wear and Failure an LA a An v an a N J Noria s 13th Annual Conference amp oe 2 n N a S RELIABLEPLANT ip i INDIANA 20015 IN o NEVZ SE ja det nm a a eCombustion Efficiency e Inefficient Seal Designs 1 eHeat Compression Stroke The Process Of Blowby oil soot fuel and contaminants accumulate on ring Q v gt O e Pressure on piston seals e Concentrations of NOx Soot and other particles in combustion chamber 2 Power Stroke e Oil Filter Efficiency oil soot fuel and contaminants e Oil Sump Size pass to oil sump cylinder wall Noria s 13th Annual Conference amp Exhibition m JS bib Ia ii 2 N 4 mA E INOA 2OLS D 2 MAY E a a A m AVR Ouick Basics j 4 j s B gt Miles Per Gallon e Driving patterns e Routes city highway mountains e High loads altitudes Extreme Te
12. ion Noria s 13th Annual Conference amp E Sy RELIABLEPLAI i Bex W xt INDIANA POMISNIN EVIA Yai ES Root Cause Root Cause Root Cause Stage sI3L1IS aJn Ie4 IO i J N Engine Failure Stage Root Cause nr i 1 sa3e15 DINNIEJ IO m ss Engine Failure Stage Ji pans a jal e amp Exhibitio SELBE de P NINE OLS Ho MEN Lai Ti haat 1 5 i x a ge tt aa A Driving Conditions Driving conditions can be catalysts to impaired oil and engine conditions But it should be emphasized that it can directly influence the extension or reduction of the oil drain interval Driving conditions include two things Where you drive How you drive v aN x 7 yy ahi N W Noria s 13th Annual Conference amp Exhibition 2 a 4 RELIABLEPLANT 1653 PA 20U5 D 2 MAU oe eerie oN el a N TII 4 lt N Heavy Duty Engine OEM Recommendations for ODI Engine ODICIassification Make Model Light Medium Severe Extreme Oil Cap Ots HP Light Medium Severe Extreme cummins 5X12 35 000 25 000 15000 44 310425P6MPG 5 65MPG smMPG isxa5 35 000 25000 15000 56 40 600 J 05 e Det DD13 50000 35 000 25000 42 350470p6MPG
13. ity grade or 5 cSt from the new oil Total base number TBN ASTM D 4739 2 5 number minimum or half new oil value or equal to TAN Water content ASTM D 95 0 5 maximum Silicone SI 15 ppm increase over new oil Sodium Na 20 ppm increase over new oil Boron B 25 ppm increase over new oil Potassium K 20 ppm increase over new oil Soot wt Midrange B and C ae n 7 7 a N nalan LIIS m A gt ri Noria s 13th Annual Conference amp Exhibition 2 n 4 0 matty N ni a 4 p 10309 ME SY R LIABLE LANT etre INDLANAZOUS N MAY J ar Pu ti a API CJ 4 HTHS viscosity requirements High Covers the Viscosity Viscosity 150 degrees C minimum Temperature laboratory High Shear determination i of the Viscosity viscosity of engine oils Viscosity mPa s Mog b Q e C ue e c BELIABLEPI P nt g Viscosity cSt Fi Fi a Deciphering the Engine Oil Options Oil Viscosity vs Temperature FEER no nl t hn een P omi FEETETTT Temperature C W n a ja mal Noria s 13th Annual Conference amp Exhibition S RELIARIEPLANT i ee INDIANAPOLIS DJ MAY ay sitt e iss ay Neutralization gt The TBN number can act as a primary indicator of the age of the oil gt TBN is a good indicator to summing up the effects of contamin
14. mperatures e Cold start conditions e Hot ambient conditions 490 F Extreme Environments e Dirt roads construction sites causing more opportunities for contaminant ingression e High air humidity e Extended Idling O Img International WorkStar INDIANA PODMISAIN EIVIAYaI E e Soot and sludge deposits can prevent the piston ring from flexing carbon jacking forcing more friction and wear e Solid contaminants increase friction and wear between moving parts e Moisture glycol and acids promote corrosion additive depletion and oil oxidation e Fuel dilution thins oil films and encourages oxidation e Incorrect engine oil used can prevent the oil from functioning effectively at extreme temperatures cold or hot elmpaired performance from additives e The quality of an engine oil with specific additives is a major contributor to it s TBN protection from corrosion Ouick Basics Noria s 13th Annual Conference amp Exhibition ep gt RELIABLEPLANT ease MNIDLENAZOLIS INo MAY JE TU a antes Internal Corrosive Attacks 5 46 3 e Oxidation e Additive depletion e Hydrolysis e Heat e Friction from particle contamination e Friction from internal components due to a lack of lubrication Oil Sludge Black Death i e Contaminants soot oxides solids e Water and acids e Higher Combustion Temperatures e Additive depletion Un m fia ie t
15. nd history Understanding the influencing factors such as the owner s driving style environment chosen engine oil and filter and engine efficiency etc can provide justification to an optimal ODI Oil Analysis is still recommended if reasonably available In Review Optimizing the Interval Oil degradation can root from engine properties driving conditions and characteristics of the oil itself The use of synthetic oil does not automatically allow the extended ODI How you drive and where you drive can significantly affect your ODI Engine properties such as oil capacity combustion efficiency aftertreatment solution options can all affect the ODI While extending oil drain intervals does save immediate costs and time it may not be the lowest cost of ownership option depending on your circumstances Extending drains can lead to higher soot and oxidation levels that increase oil viscosity which would negatively impact fuel economy In Review Optimizing the Interval In many cases the optimal drain interval may not be reached prior to recommendations given by the OEM TBN can be a good measure of the quality of the oil and when it s reached it s condemning limit Using oil analysis or smart estimations based on all the known factors can be effective in providing a good ODI to follow Potential for a onboard calibrated solution in adoption with current and or added onboard sensors to pro
16. nference amp Exhibition d O BELABLEPLANT 655 INDIAN APODISNIN MAY I lEs ia ae Optimizing the Interval Weighing the Factors Miles ODI Miles gallon 40 000 35 000 History of Engine Problems Healthy Oil Analysis Readings Aged and High Mileage on Engine Higher MPH Averages 30 000 Heavy Loads High Elevation Ouality of Filters Lubricants Cold Starts Idling Unhealthy Road Conditions Higher MPG Efficiency 25 000 20 000 15 000 un 7 JA 7 a N t n ad a NT ipa 2m gt YRELIABLEPLANT 16555 jatta Optimizing the Interval Weighing the Factors INDIANAPRGOLISAIN EIVIA Yai 3 Miles ODI Miles gallon His O 40 000 Aged a Yen Ne i Pr Colg St n Say Mitan len ats lay load H Be o 3 I Jj 35 000 we Unhon leva Sie 9 th lon ition n 000 Salt Oj 4 25 000 Vity op Avera I Dg Hepa iter 88s er G P Ubria icien ts 20 000 15 000 a aN a m Dom p INDIANAPOLISAIN BVIAYal A Different Approach between Fleet Owners and Owner Operators e Fleet Owners Huge potential for development of truck based and route based optimum ODI justification through oil analysis and trend analysis Keeping a close log of the results based on the driver can be an influencing factor as well e Owner Operators Potential for reasonable estimations due to the owner s ability to monitor and understand their own truck s tendencies a
17. pg hange Centrifuge Filter Me E MUN aen Part 26054670904 ith Oil Change With Oil Change vith Oil Change Heavy Duty International truck manuals EE DUE EEG 18 000 mi 298 000 km specify that with their 2010 MaxxForce 50 000 Extended drains possible with oil sampling and review engines if you have obtain 6 5 miles per s gallon or greater then the recommended 64 40 oil drain interval can be as much as 30 000 40 000 miles 70 000 32 200 4 10 000 This is an improvement from previous MaxxForce engines that specified a TT T Gn 65 T 25 000 miles oil drain interval Drain intervals with centrifuge oil filer N d Drain intervals without centrifuge oil filter 14 ef MaxxForce Service Manual KN w e amp Exhibiti apex 2 S RELIABLEPLANI ig i NONAPOLS 2 MAME Mi Aaa Sealing Challenges e There are a few challenges engine oil faces that are the unpredictable factors to when and where it will cause engine failure Coolant Contamination e Glycol and Water Leads to oxidation corrosion additive distress loss of dispersancy premature filter failure Just 0 4 percent coolant containing glycol in diesel engine oil is enough to coagulate soot lead to sludge deposits oil flow restrictions and filter blockage Piston Blow by e Fuel Dilution Contains unsaturated aromatic molecules that are pro oxidant leading to TBN
18. vide a highly effective solution to flexible oil drain interval a Thanks and Questions e Any Ouestions
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