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SHELL FLEET TECHNOLOGY TOUR
August 29, 2011
VALUE DELIVERY THROUGH SERVICES
OIL CONDITIONING MONITORING PROGRAM
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SETTING UP AN EFFECTIVE OIL ANALYSIS PROGRAM
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Why Conduct Oil Analysis?—Identify and measure oil contamination—Monitor product performance—Monitor component wear
Potential Benefits—Increase equipment availability by decreasing equipment
downtime—Increase overall component life span—Monitor product performance and optimize oil service
intervals—Decrease fuel and oil consumption
What Equipment Should You Sample On?—Equipment integral to a proactive maintenance program
OIL ANALYSIS PROGRAM SAMPLING PROCEDURES
Three Easy Steps:
1. Take a Proper Sample2. Supply Sample
Information3. Send Samples to the
Lab
TAKING A PROPER SAMPLE IS CRITICAL
Sampling Procedures— Equipment should be run at
temperature prior to sampling— Take sample within 30 minutes
of shutdown— Whenever possible take
sample while lubricant is circulating (sample valve only)
— Take samples the same way each time….
Consistency Is the Key
SUPPLY SAMPLE INFORMATION
Provide Sample Information—Fill out forms as completely as possible—Fill out label on the sample container—When possible, provide an equipment list
to the lab before sampling starts (preloaded in lab’s computer system)
Oil samples must be accompanied with:—Sample origin (Name and Address)—Sample date—Unit or engine identification—Unit hours or miles—Oil hours or miles—Quantity of oil added this sampling period—Quantity of oil low (based on dipstick)—Oil brand name and viscosity grade
Take the sample today, send it today
PROPER SAMPLING INTERVALS AND THE RIGHT TESTS ARE KEY
Engine Oil Testing Components—Spectrographic Analysis of
Metals—Fuel Dilution (% volume)—Fuel Soot (% weight)—Water (% volume)—Viscosity (cSt @100° C)—Glycol from coolant
(positive / negative)—Total Base Number (TBN)
—Total Acid Number (TAN)
Sampling Considerations:—Operating priority of equipment—Current PM, lube and filter schedules—OEM recommendations or
requirements—Environmental influences (dust,
water, etc.)—Current or historical problems of
specific or like equipment—Specific goals of program objectives—Adjust as appropriate
SPECTROGRAPHIC ANALYSIS HELPS US TRACK 3 KEY THINGS
Component wear metals:—Iron, Chromium, Nickel,
Molybdenum, Aluminum, Lead, Copper, Tin, Silver
Contaminants: —Silicon, Sodium, Boron,
Potassium
Additives:—Phosphorous, Zinc,
Calcium, Barium, Boron, Molybdenum, Magnesium
TESTING CAN ALSO REVEAL PRESENCE OF FUEL, SOOT, AND WATER
Typical Causes of Fuel Dilution—Worn, leaking, damaged injectors—Improperly adjusted fuel system
settings—Excessive idling / lugging
Fuel Dilution Effects—Decrease in viscosity:
— 5% = approx. 1 SAE Grade Loss
— Reduced lubrication— Increased wear rates
—Decreased fuel efficiency
Causes for High Soot—Incomplete combustion—Improperly adjusted fuel system
settings—Restricted air intake or exhaust—Worn or mismatched injectors—Excessive idling and/or lugging—Deficient fuel properties
Soot Actions/Effects—Naturally attracted into gel
formations—Hardened by heat to form deposits—Loads and depletes dispersant
additives—Plugs oil filters—Increases viscosity
Water Sources/Causes —Bulk oil contamination—Low operating temp.—Defective seals / gaskets—Cracked head / block, liner, injector
tube, etc.—Defective water pump—Oil cooler, heat exchanger tubing
Actions/Effects—Surface corrosion / rust —Changes in viscosity—Loss of additive performance—Increased sludge—Decreased filter performance—Increase in oxidation and foam
tendency
DATA INTERPRETATION: READING REPORTS
Types Of Applied Limits:— Set Values – Minimum
or Maximum— Set by component
OEM’s and analytical labs
— Values vary by type of components, equipment make/model, application
—Trend Analysis – for change
— Values developed based on allowable deviations from analytically established baseline
— Combinations of the above
TAKING ACTION ON THE DATA
When A Change Occurs:— Look for corresponding
cause or reason— Contaminant, viscosity
change, etc.
— Look for a confirming related change
— Increased viscosity with increased solids, etc.
— Look for identifying components
— Water + Na + B or K = Cooling System Leak
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EXAMPLE: OIL ANALYSIS HELPS FLEET CUSTOMER SAVE OVER $46,0000 IN ENGINE REBUILDS *
Large Shell Fleet customer in US worked with Shell to establish oil analysis program as part of maintenance cost containment/reduction measures
Specific focus on in-warranty equipment sampling at PM intervals to identify potential issues (particularly signs of high wear) prior to warranty expiration
Testing results indicated abnormal results indicating excessive bearing overlay wear in 3 units
Resulting action required: 2 engine overhauls in-frame
1 engine replaced
Since issues were spotted while under warranty, there was no cost to the fleet for repairs
One of the units repaired was at 486K miles with warranty expiring at 500K miles!*Savings indicated specifically calculated from actual customer value delivery example
KEYS TO A SUCCESSFUL USED OIL ANALYSIS PROGRAM
Clearly defined goals and program requirements
Representative samples
Complete sample information
Frequent customer-laboratory contact