Maintaining Engines

8/2/2019 Maintaining Engines

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Engines

Maintaining the Life of Your Engine byOperating in a Waterless CapacityMike Tourville

O ,a waterlesscOOlant can leadtO significantfuel saving andmaintenance, oo o o . th ohook o.

EnginE manufacturErs havE bEEn contEnding

with heat transer issues or more than 100 years with a

multitude o modications: powerul ans, larger radiators

and applying engine perormance limitations. The struggle

to gain eciency and meet tighter emissions standards

while controlling costs is an ongoing challenge. Despite

the advances in engine cooling technologies, one aspect has

remained relatively unchanged or more than 50 years: the

basic ormula or coolant is still a 50/50 mix o ethylene

glycol and water. Additives have improved and longer

lie coolants have evolved, but water has been a constant

element. Water is a good thermal conductor, but it has its

drawbacks and limitations: corrosion and a low boiling

point, to be more specic. Cooling systems are designed

to work within the limitations o water, and a lot o energy

is consumed to keep the coolant rom reaching its boiling

point. A simple answer to consider has been developed to

address these issues: to eliminate the problems associated

with water, remove the water. The absence o water in awaterless heavy-duty coolant (HDC) prevents corrosion

and avoids electrolysis. Perhaps the most important aspect

is the high boiling point o 375 F, which translates into a

large separation o the coolant operating temperature and

the boiling point o the coolant.

What is good about water is its cheap and has

superior thermal conductivityas long as it remains

a liquid. Water retains only 4 percent o its thermal

conductivity when it changes into vapor. On the other

hand, water is a poor choice because its boiling point

is too low, and there is very little separation between

the operating temperature o the coolant and the boilingpoint o water. I the coolant boils over, vapor pockets

create an insulating barrier between the metal and the

coolant. The low boiling point o water becomes the

ailure temperature o traditional cooling systems. With

its high boiling point o 375F, a waterless HDC has

the capacity to saely operate at higher temperatures

without overheating, resulting in less downtime.

Maintenance SavingsBecause this type o heavy duty coolant does notcontain water, electrolysis and corrosion are eliminated.

This shows what happens when the additive buildup collects in a coolant flter. This is avoided witha waterless coolant. Images courtesy o Evans CoolingSystems.

20 WasteAdvantage Magazine March 2012

As Seen In

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m e Le Y Ee y ope Wele

Water is the root cause o corrosion in engine

cooling systems, and even the latest inhibitor

technology oten ails to prevent componentailure. The most expensive corrosion problem is

cavitation o cylinder liners. Cavitation erosion

is caused by collapsing bubbles that cause

erosion over the surace o the exterior o the

cylinder liners. The resulting erosion eventually

penetrates the wall o the cylinder and permits

coolant to fow into the cylinder.

The large separation between the operating

temperature and the boiling point o waterlessHDC stops cavitation erosion o cylinder liners.

In a pressurized system, the water-based

coolant must be maintained at a temperature

below the boiling point o water to keep the

system unctional. The absence o water means

that vapor will not be ormed, which can cause pressure in the

system. Typically, cooling systems have up to a 15 lb. pressure

cap to raise the boiling point. Each pound o pressure raises

the boiling point by about three degrees, which means a 15

lb. cap would raise the boiling point to about 257F. This is still

dangerously close to the operating temperature o the coolant

in an engine, especially under hot and dusty environments. The

waterless HDC ormula operates under a much lower pressure,

decreasing stress on hoses and gaskets, reducing the likelihood

o leaks. Additionally, a lower pressure brings an added saety

element to the operator. Opening the cap on a hot radiator can

result in injury to anyone within close proximity o the radiator.

The endurance o the engine is improved by maintaining

control o engine metal temperatures at all times. The absence

o cavitation erosion extends the lie o cylinder liners and

SAE TypE II

FuEl TESTThe SAE Type II

Fuel testing using the

waterless coolant and

215 thermostats and

eliminating the an time

variable, still produced a

3 percent improvement

in uel eciency. Recent

emissions testing showed

a reduction o 3.6 percent

in CO2emissions and a

4 percent uel economy

improvement in a test

perormed by Emisstar

in August 2011. Emisstar

provides independent

third party testing services

or the development o

sustainable transportationtechnology strategies.

Boiling points or the waterless HDC, 50/50 EGW and water.

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coolant pumps. Pump seals last longer because there are no abrasive additive

deposits on the seals. Water also contributes to pump and cylinder liner

cavitation and corrosion, as well as hot spots that can damage engines.

A waterless coolant can last orever, as long as it doesnt become contaminatedwith water. With a waterless HDC, periodic coolant replacement and disposal

is not necessary and supplemental coolant additives (SCAs) are not required.

HDC additives remain stable and in solution during storage and use resulting

in no abrasive additive deposits. The coolant will not evaporate which means

the occasional topping o can be greatly reduced.

Fuel EconomyMost people wouldnt associate coolants with uel economy. The energy that

it takes to maintain coolant temperatures below the boiling point o water is a

huge waste o uel. The huge separation between the operating temperature o the

coolant and the boiling point allows an extra cooling capacity that your system

already has. When the coolant temperature can be saely raised, the result is a

more ecient heat transer rom radiator to the ambient air. This allows an engine

to run continuously under harsh conditions using less an power and saving uel.

Independent evaluations and feet testing have consistently demonstrated ueleconomy improvements between 3 to 9 percent.

Due to the severe perormance requirements reuse vehicles encounter daily, such

as constant starts and stops, heavy loads and the lack o ram air to cool the engines,

uel savings is adversely aected. A waterless coolant allows a reduction o an-on

time by up to 40 to 50 percent. The ans on heavy-duty diesels draw considerable

horsepower, thereore minimizing an operation leads directly to signicant uel

savings.

Along with reducing uel consumption, decreasing emissions, maintenance

savings are also achievable with a waterless HDC. The waterless ormula

does cost more per gallon than a traditional 50/50 ethylene glycol and water

mixture. However, once in use, the uel saving and maintenance benets have

John DEErE

CAvITATIon TEST

In a recognized test (the John Deere Engine Cavitation Test) perormed in April 2009 by a third party

laboratory, the results showed that waterless coolants provided superior protection against cylinder liner

cavitation erosion. The waterless coolant perormed more than 70 percent better than any other coolant

tested in preventing cavitation erosion. It is now approved as an ASTM standard test method.

Cylinder Liner cavitation erosion can be virtually eliminated with waterless Heavy Duty Coolant.

WasteAdvantage Magazine March 2012 23

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m e Le Y Ee y ope Wele cpy

demonstrated an ROI o 6 months or less, not to mention reduced down time. Thats a considerably shortpayback period, and an investment well worth looking into. | WA

Mike Tourville is Sales and Marketing Director for Evans Cooling Systems, Inc. (Sharon, CT). He can be reached

at (860) 668-1114 or via e-mail at [email protected].

CASE STuDy:

vEolIA EnvIronmEnTAl SAvES FuEl

Veolia Environmental Services in Florida was

trying to reduce uel consumption. They did a year-

long evaluation using Evans Cooling Systems

heavy-duty waterless coolant beginning in October

2009 and ound that waste vehicles in Sheboygan,

WI saved in the range o 4.4 percent uel. Furthertesting in Apopka, FL demonstrated savings in

excess o 9 percent due to reduced an time when

an temperature is raised to 230 F. The coolant

has paid or itsel within a ew months and no

overheating issues were reported. Harold Graves,

Regional Maintenance Manager, East North America

says, Were very happy with the way Evans has

presented their product and services. They are data

purists, and the results are indisputable. Veolia is

beginning to schedule the rest o the regional feet

and plans to continue to expand the conversions to

other areas. Were looking at converting o-highway

equipment in the northeast, not only or uel saving

purposes, but to also improve perormance and

productivity.

Skip Webber, Area Maintenance Manager, Solid

Waste, North America, agrees, The waterless

coolant is a great product and were seeing

signicant uel economy improvement. We havent

had a problem with any o the converted trucks,

including overheating or maintenance issues.

Thermal conductivity o the liquid and vapor phases o a water-based coolant versus a waterless HDC.

2012 Waste Advantage Magazine, All Rights Reserved.Reprinted rom Waste Advantage Magazine.

Contents cannot be reprinted without permission rom the publisher.

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Maintaining Engines