Oil Life Extension 16 Slide

CONDITION MONITORING

ENHANCEMENT OF ENGINE OIL

& FILTER LIFE AND

OVERALL

PERFORMANCE OF ENGINE Diesel Engines operational efficiency largely depends on the performance of following: Fuel system, Lubricating Oil system & Air System. Thus ensuring use of high quality Diesel, quality air intake, good lubricating oil & monitoring its condition consistently, can fetch better efficiency, longer life of Diesel engine & its component & huge saving on oil & filters.IntroductionProspectiveEngine built in system has its own limitation & thus need frequent change of filters, oil to maintain the condition of oil, fuel & air.

On further study of available literatures, review of technologies & discussion with OEM & oil manufacturer, it was felt that there is a scope for extending oil drain interval / filter life & yet maintain the desired condition through scientific approach. It was also understood that by exploring all possibilities in line with available guidelines from OEM & Lubricant Manufacturer & adopting new technology, a substantial benefit can be achieved.Some prominent achievable benefitsDirect benefits Higher Engine Oil life Higher filters life Higher fuel economy Extended overhaul period Higher availability of Equipment All the above will lead to Huge cost savingOther benefits: Lesser Engine related trouble Lesser Component failure Lesser Emission (Environmental Benefit) Higher overall engine efficiency Lesser use of Natural Resources & Lesser waste disposal hazard

With a view to achieve all the benefit listed above an initiative was undertaken with all necessary, precautionary measures & prior approval, to establish extended service life of Oil & Filters.Approach Following steps were undertaken to establish oil drain interval & filter life. Guidelines were obtained from OEM (Cummins) for extending oil drain interval. Guidelines were obtained from Oil manufacturer for rejection criteria of Oil.The matter were also discussed with industry oil experts for further clarification and revalidation. Based on the Guidelines provided by Cummins & Shell India ltd, Engine oil samples were collected carefully & tested at oil manufacturers laboratory in stages.Based on the test reports & interpretation of results, oil life was extended in stages up to 800 hrs as all parameters were within limit. Further possibility was explored through available technology & few modern gadgets like on-line oil, Fuel & Air purifier were added in two RTG for a trail run. All parameters including oil sample test reports were closely monitored till 1600 hrs in stages & found to be well within limit.Oil was replaced after 1600 hrs of run & it was decided to check the internal condition of Engine through endoscopy, as engine had covered more than 5500 hrs of total running.

On line Oil Purifier

On line Fuel Purifier

On Line Air PurifierShell India ltd. who provides such special services (to its customers) were invited & carried out the video endoscopy for the engines.Internal condition of engines was found to be very good during the Endoscopy.On further monitoring of parameter, later it was decided to defer the filters replacement schedule to double of its recommended life.

Based on the success of the trail, online Air, Fuel & Oil purification units were installed in all RTG.

Video check Endoscopy instrument Major Benefits Achieved : Cost savings of $ 68,900 in Year 2010 on Engine Oil & Filters only. Cost saving of $ 22,358 in Year 2010 due to better Fuel Economy.Also benefits like reduction in overall maintenance cost, lesser engine related trouble, higher equipment availability, less manpower requirement, lesser use of natural resources, & many other benefits achieved.Cost of Implementation - $. 83,850 only.Overall ROI Approx One year.Thank You