SHELL FLEET TECHNOLOGY TOUR
August 29, 2011
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VALUE DELIVERY THROUGH
SERVICES
OIL CONDITIONING
MONITORING PROGRAM
SETTING UP AN EFFECTIVE OIL ANALYSIS PROGRAM
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
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OIL ANALYSIS PROGRAM SAMPLING PROCEDURES
Three Easy Steps:
1.
2.
3.
Take a Proper Sample
Supply Sample
Information
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
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
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)
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
Fuel Dilution Effects
—Worn, leaking, damaged injectors
—Improperly adjusted fuel system settings
—Excessive idling / lugging
—Decrease in viscosity:
— 5% = approx. 1 SAE Grade Loss
— Reduced lubrication
— Increased wear rates
—Decreased fuel efficiency
Causes for High Soot
Soot Actions/Effects
—Incomplete combustion
—Improperly adjusted fuel system settings
—Restricted air intake or exhaust
—Worn or mismatched injectors
—Excessive idling and/or lugging
—Deficient fuel properties
—Naturally attracted into gel formations
—Hardened by heat to form deposits
—Loads and depletes dispersant additives
—Plugs oil filters
—Increases viscosity
Water Sources/Causes
Actions/Effects
—Bulk oil contamination
—Low operating temp.
—Defective seals / gaskets
—Cracked head / block, liner, injector tube, etc.
—Defective water pump
—Oil cooler, heat exchanger tubing
—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
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
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KEYS TO A SUCCESSFUL
USED OIL ANALYSIS PROGRAM
Clearly defined goals and
program requirements
Representative samples
Complete sample
information
Frequent customerlaboratory contact