Engine Oil Analysis - Georgia Department of Transportation - AASHTO … · Oil Analysis for Extended Drain Intervals ... 2014-16 Charlotte Area ... •All results within specification

Oil Analysis for Extended Drain Intervals

John C. [email protected]

July 25, 2017

Agenda

1. Purpose and Objective

2. Engine Oil

3. Experimental Program

4. Baseline Oil Analyses

5. Analysis Program

6. Analysis Results

7. Recommendations


Purpose

Understand how (fast) engine oil changes over time to investigate the potential for extending drain intervals.

Objective

Push the drain interval limit while maintaining sufficient oil quality to NOT endanger the engine.

2. What is engine oil?

A formulated blend of base oil and various additives

Base oil (75 to 99% by volume)• Petroleum based derived from crude – conventional or mineral

• Polyalphaolefin (PAO) synthesized hydrocarbon – synthetic oil

• Mixture of the two – synthetic blend oil

2. What is engine oil?

Additives (1 to 25% by volume)• Surface Protection

• Anti-wear

• Corrosion Inhibitor

• Detergent

• Dispersant

• Friction Modifiers

• Performance

• Pour Point Depressant

• Seal Swell Agent

• Viscosity Modifier

• Protective

• Antifoaming Agent

• Antioxidant

2. What happens as oil ages?

1. Physical Change

• Viscosity increase – soot contamination through blow-by

• Viscosity decrease – mechanical degradation (molecular shearing) or dilution

• Corresponding density changes

2. What happens as oil ages?

2. Chemical Change• Oxidation – reaction of base oil with oxygen

• Additive Depletion – decomposition or mass transfer

• Thermal and/or Compressive Heating

3. Contamination• Water

• Dirt

• Fuel

• Soot

• Glycol

• Wear metals

Changes are not independent One source – if left long enough –

may have a domino effect

3. Analysis Equipment

• Benchtop analysis to avoid time delay in results

• OSA4 TruckCheck ($50k) and Spectro Scientific MicroLab 30 ($80k)• Chemical analysis by infrared spectrometer – TBN, oxidation,

nitration, water, soot, glycol

• Viscosity (40 and 100C) by Kinematic Viscometer

• Metals analysis by Optical Emission Spectrometer

• Perform ~3 analyses per hour

• Consumables• CheckFlush fluid

• Standardization fluids

3. Threshold Oil Parameters

• Ideally set specific to each engine/equipment type

• Sump capacity

• Operating conditions

• General min/max values applicable across the fleet

• Tended towards conservative values

• Set in consultation with Mr. Diego Navarro

• Used to trigger an oil change

3. Threshold Oil Parameters

Full list of thresholds in project report

Key Parameters

1. TBN: 4 mg KOH/g

2. Viscosity: 12.5 – 16.3 cSt (40 wt oil)

3. Silicon: 40 ppm (10 ppm if dirt)

4. Aluminum: 15 ppm (with Si)

5. Iron: 100 ppm

6. Potassium and Sodium (glycol): 50 ppm both

Agenda


2. Engine Oil



5. Analysis Program

6. Analysis Results

7. Recommendations


Three oil types

1. Conoco HD Fleet Supreme conventional 15W-40

2. Xtreme Fleet synthetic blend 15W-40

3. Shell Rotella T6 full synthetic 5W-40

Analyzed samples of fresh oil and compared with manufacturer published values

1. Conventional: 18 bulk tank samples

2. Synthetic blend: 24 bulk tank samples

3. Synthetic: 30 bulk tank & 12 retail samples


Conoco HD Fleet

SupremeConventional 15W-40

Xtreme FleetSynthetic Blend 15W-40

Shell Rotella T6Full Synthetic 5W-40

Published

Avg.

Measured Published

Avg.

Measured Published

Avg. Measured

Div 10

Bulk Tank

Div 3

Bulk Tank Retail A Retail B

Viscosity, 40C

(cSt)115 N/A 116.4 100.2 87 N/A 81 N/A N/A

Viscosity, 100C

(cSt)15.2 14.99 15.8 13.9 14.2 12.84 13.2 12.98 13.61

Viscosity Index 135 N/A 144 141 169* N/A 165 N/A N/A

TBN

(mg KOH/g)9.5 9.33 10.1 8.61 10.6 9.53 9.53 9.45 9.38

* Value not published, calculated value

5. Analysis Program

2014-16 Charlotte Area

• Analyzed oil from all machines in 4 classes

• 200 hr / 5,000 mile interval

• 47 total machines

• Selected 3 to 4 machines in each class for extended drain intervals

• Ultimately put all IMAP trucks on extended intervals

• Conventional & synthetic oils

2016-18 Wilmington Area

• 4 equipment classes

• 13 total machines

• 3 to 4 machines in each all for extended intervals

• Included Navistar DT466 engine to continue study

• 3 additional engines to add to the previous study

• Blend & synthetic oils

5. Studied Equipment

2014 – 2016 Charlotte Area (Div. 10)

Class 0209International 7300

Navistar DT466 7.6L I6

Conventional

Class 0210Ford F350

Powerstroke 6.4L V8

Powerstroke 6.7L V8

Rotella T6 synthetic


2014 – 2016 Charlotte Area (Div. 10)

Class 0303New Holland T6030

NH 6.7L 6-cylDeere 6420

Deere 4.5L 4-cyl Conventional

Class 0311Deere 7600

Deere 6.8L 6-cyl

Deere 6140M

Deere 4.5L 4-cyl

Conventional


2016 – 2018 Wilmington Area (Div. 3)

Class 0205

International 7300Navistar DT466 6.7L I6

2 using Rotella T6 synthetic

2 using synthetic blend

Class 0212

Mack GU713MP7-395C 11L I6

Synthetic blend


2016 – 2018 Wilmington Area (Div. 3)

Class 0314

JCB 3C15JCB 444 4.4L 4-cyl

Synthetic blend

Class 1854

Hyundai R140LC-7AMitsubishi D04FC-TAA 4.2L 4-cyl

Synthetic blend

Agenda


2. Engine Oil



5. Analysis Program

6. Analysis Results

7. Recommendations

6. Analysis Results

Equipment

No. of Samples

Analyzed

No. of Machines

Sampled

0209 Crew Cab Chassis 178 13

0210 IMAP Truck 358 12

0303 Mowing Tractor 162 8

0311 Sideboom Mowing Tractor 252 14

0205 Single-Axle Dump 3 1

0212 Tandem-Axle Dump 42 3

0314 Backhoe Loader 23 3

1854 Excavator 21 3

Total 1,039 57

Collected 3 samples (150 ml) at pre-determined intervals and averaged the results

6. Analysis Results

• TBN key to chemical change

• Time (use) dependent

• Viscosity decrease due to fuel dilution

• Specific to engine type

• Contamination was not an issue (water, glycol, soot)

• Very little wear metals produced

• Copper passivation

• Isolated engine issues

6. TBN – Conventional Oil

• Tractors performed similarly

• TBN is use dependent

• TBN decrease 0.4 per 100 hrs

• Threshold at 1350 hrs

y = -0.0039x + 9.37

R² = 0.4263

0

2

4

6

8

10

12

0 100 200 300 400 500

To

tal

Ba

se N

um

ber

(m

g K

OH

/g)

Oil Age (hrs)

0303 & 0311 Mowing Tractors

0311

0303

• TBN is not use dependent

• TBN remained unchanged to 11k miles

y = -0.00002x + 9.22

R² = 0.0171

0

2

4

6

8

10

12

0 2,000 4,000 6,000 8,000 10,000 12,000

To

tal

Ba

se N

um

ber

(m

g K

OH

/g)

Oil Age (miles)

0209 Crew Cab Chassis

0209

215-6377

6. TBN – Synthetic Blend

Preliminary Results

y = -0.0044x + 9.1993

R² = 0.3586

0

2

4

6

8

10

12

0 100 200 300 400

To

tal

Ba

se N

um

ber

(m

g K

OH

/g)

Oil Age (hrs)

0314 Backhoes and 1854 Excavators

0314

1854

y = -0.00034x + 9.83

R² = 0.97367

y = -0.00040x + 9.70

R² = 0.96948

0

2

4

6

8

10

12

0 2,000 4,000 6,000 8,000 10,000 12,000

To

tal

Ba

se N

um

ber

(m

g K

OH

/g)

Oil Age (miles)

0212 Tandem Axle Dump Trucks

• ~0.4 decrease per 100 hrs

• Threshold at ~1200 hrs

• ~0.4 decrease per 1,000 miles

• Threshold at ~14k miles

6. TBN – Synthetic

• More variable

• Faster (?) to threshold

• Fairly consistent / predictable

• 12k miles to TBN of 4

y = -0.0004x + 9.16

R² = 0.5807

0

2

4

6

8

10

12

0 2,000 4,000 6,000 8,000 10,000 12,000 14,000

To

tal

Ba

se N

um

ber

(m

g K

OH

/g)

Oil Age (miles)

0210 IMAP Trucks - 6.4 L

y = -0.0004x + 9.10

R² = 0.824

0

2

4

6

8

10

12

0 2,000 4,000 6,000 8,000 10,000 12,000 14,000

To

tal

Ba

se N

um

ber

(m

g K

OH

/g)

Oil Age (miles)


6. TBN – Conv. vs Synthetic

One oil drain in two IMAP trucks with 6.7L engine

0

2

4

6

8

10

12

0 2,000 4,000 6,000 8,000 10,000 12,000 14,000

Tota

l B

ase

Nu

mb

er (

mg K

OH

/g)

Oil Age (miles)

Conventional

Synthetic

6. Viscosity – Conventional Oil

• 0311 might trend upward

• All results within specification

• Some low viscosity

• Not time (use) dependent

6

8

10

12

14

16

18

0 2,000 4,000 6,000 8,000 10,000 12,000

Vic

osi

ty a

t 1

00

C (

cSt)

Oil Age (miles)

0209 Crew Cab Chassis

0209

215-6377

6

8

10

12

14

16

18

0 100 200 300 400 500

Vic

osi

ty a

t 1

00

C (

cSt)

Oil Age (hrs)

0303 & 0311 Mowing Tractors

0311

0303

6. Viscosity – Synthetic Blend

Preliminary Results

6

8

10

12

14

16

18

0 100 200 300 400

Vis

cosi

ty a

t 1

00

C (

cSt)

Oil Age (hrs)

0314 Backhoes and 1854 Excavators

0314

1854

6

8

10

12

14

16

18

0 2,000 4,000 6,000 8,000 10,000 12,000

Vis

cosi

ty a

t 1

00

C (

cSt)

Oil Age (hrs)

0212 Tandem Axle Dump Trucks

6. Viscosity – Synthetic

• Low viscosity at 1k miles

• Fuel dilution (known to the 6.4L engine)

• At the SAE min for 40 wt oil

• Very consistent

6

8

10

12

14

16

18

0 2,000 4,000 6,000 8,000 10,000 12,000 14,000

Vis

cosi

ty a

t 1

00

C (

cSt)

Oil Age (miles)


6

8

10

12

14

16

18

0 2,000 4,000 6,000 8,000 10,000 12,000 14,000

Vis

cosi

ty a

t 1

00

C (

cSt)

Oil Age (miles)


6. Oil Contamination

0.0

0.1

0.2

0.3

0.4

0.5

0.6

0.7

0.8

0.9

1.0

0 100 200 300 400 500

Co

nta

min

an

t C

on

ten

t (%

)

Oil Age (hrs)

0311 Sideboom Mowing Tractors

Soot (3% max)

Water (0.5% max)

Glycol (0% max)

6. Wear Metals – 0303 Tractors

0

5

10

15

20

0 50 100 150 200 250 300

Alu

min

um

(p

pm

)

Oil Age (hrs)

0

20

40

60

80

100

120

0 50 100 150 200 250 300

Iro

n (

pp

m)

Oil Age (hrs)

0

10

20

30

40

50

60

70

0 50 100 150 200 250 300

Co

pp

er (

pp

m)

Oil Age (hrs)

0

2

4

6

8

10

12

0 50 100 150 200 250 300

Ch

rom

ium

(p

pm

)

Oil Age (hrs)

6. Copper – New Tractors

0

10

20

30

40

50

60

70

0 100 200 300 400 500 600

Cop

per

(p

pm

)

Tractor Age (hrs)

838-0311

838-0312

838-0313

838-0314

7. Recommendations

Class Engine

Recommended

Drain Interval Comments

0209 Navistar DT466 10,000 miles Likely longer, need additional data

02106.4L 5,000 miles Viscosity / Fuel Dilution

6.7L 10,000 miles Consider conventional oil

0303

0311All 500 hrs Likely longer, need additional data

Opportunity to extend drain intervals without significant danger of unacceptable oil quality

7. Recommendations

Class Engine (Sump) Count

Avg Ann.

Use

Est. Cost

per Oil

Change

Estimated Annual Savings

Oil Changes

per Machine

Annual

Cost

Annual

Oil (gals)

0209 Navistar DT466 (30) 164 10,187 mi $ 250 1 per yr $ 41,000 1,230

0210

PwrStrk 6.4L (15) 22 28,040 mi $ 170 None $ 0 0

PwrStrk 6.7L (13) 55 33,014 mi $ 170 3 per yr $ 28,050 536

0303

NH 6.7L (22) 64 216 hrs $ 300 None $ 0 0

Deere 4.5L (16) 54 302 hrs $ 300 1 per yr $ 16,200 216

0311

Deere 6.8L (24) 43 420 hrs $ 300 1 per yr $ 12,900 258

Deere 4.5L (16) 20 564 hrs $ 300 1 per yr $ 6,000 80

NH6.7L (22) 55 387 hrs $ 300 1 per yr $ 16,500 302

Estimated Annual Savings $ 120,650 2,622

Take Aways

1. Benchtop analyzers costly, but work well

2. Conventional oil performed very well

3. Engine influenced oil performance

4. Chemical change the driver

5. Extended drain intervals worth considering

6. Potential for significant savings

Oil Analysis for Extended Drain Intervals

John C. [email protected]

July 25, 2017

Engine Oil Analysis - Georgia Department of Transportation - AASHTO … · Oil Analysis for Extended Drain Intervals ... 2014-16 Charlotte Area ... •All results within specification

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