heavy duty engine oils-field trials

7/18/2019 Heavy Duty Engine Oils-Field Trials

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Copyright of Shell Global Solutions

FIELD TRIALSKEY ELEMENT OF R&D AND OEMCO-OPERATION

Frank Machatschek

Product Application Specialist, Europe




Why Field Trials? Our Motivation (1)

Key element of Product Development and Performance Demonstration Real world testing ultimate proof of performance

Test limits in tough operating conditions to ensure right performance

Ensure product will deliver what we claim

Focus on:

Wear protection AND cleanliness

Extended oil drain capability

EATS compatibility

Fuel economy

Long term performance

Helping customers to use the right

product and solving problems

hence reducing operating costs




Why Field Trials? Our Motivation (2)

Key element of co-operation with leading truck OEMs Joint testing of prototype engines and engine oils, joint engine inspections at EOT

Understanding of future hardware needs

Ability to unleash the full potential of advanced lubricants

Co-op with Mercedes-Benz Trucks:

Germany

China

India

South Africa

UAE

USA

OEMs appreciate technical support




Mercedes- Benz Supplier Award 2014 Goes To Shell

March 2015: Shell received Mercedes-Benz Supplier Award 2014 atDaimler HQ Germany in the “Partnership” category for outstanding

performance

Wendelin Wolbert (Vice President Daimler International Procurement

Systems) with Shell Global Key Account Management




Rimula R6 LM/LME 5W-30 in 4 MB Citaro O530 G, SOT: 07/2008 Demanding conditions, incline up to 12%, 300 m stop and go

Fuel consumption up to 65-70 L/100 km, but only GVW 29 to

Engine milage: up to 473.000 km

ODI recommended: 60.000 km, ODI field trial: 120.000 - 147.000 km

3 oil drains in 7 years !!!

(1) Extended Oil Drain Interval And Long-term Performance




Extremely low wear rates

Fe

[ppm]

Engine Milage [km]

Fe Limit, „elevated“: 200 ppm

(1) Extended Oil Drain Interval And Long-term Performance

Fe Limit, „high“: 250 ppm

Bus #7142

Bus #7143Bus #7144

Bus #7145

0

100

200

300

0 100,000 200,000 300,000 400,000 500,000




(2) Engine Cleanliness And Extended ODI

Rimula R6 LM 10W-40 in 3 MB Actros 5.000 m altitude

Rugged off-road, incline up to 15%

50-60 tonnes

2.000 ppm S in fuel

Fuel consumption > 100 L/100 km





Turbocharger deposits and damages Cost of turbocharger ~ 1.600 US$

Latest model T/C even more costlyMineral oil 15W-40

Rimula R6 LM 10W-40





0

100

200

300

0 100 200 300 400 500 600

Operating Window:Recommended ODI: 250 hrs

Limit Fe Wear high: 250 ppm


Oil Milage [hrs]

Fe

[ppm]




Each new wave of emission legislation (up to Euro 3) has resulted inincreased stress on the oil due to higher soot levels

Retarded injection and EGR

Soot load has increased by over 100% from API CG-4 to API CI-4

Possible effects: increased wear and oil thickening

(3) Soot Handling Capability




Rimula R6 LM 10W-40 in 11 MAN Euro 1 D0826 engines, 6,8 L, 198 kW a) High soot loading and b) heavy oil deposits in air compressor

ODI from 30.000 km to 60.000 km with Rimula R6 LM 10W-40


0

2

4

6

8

10

0 10,000 20,000 30,000 40,000 50,000 60,000

Soot in oil [%]

Oil Milage [km]

Normal soot level

Extremely high soot level




Air compressor discharge pipes: same application but different oil


Conventional Oil 15W-40

after 50.000 km

Rimula R6 LM 10W-40

after 100.000 kmRimula R6 LM 10W-40

after 50.000 km




Rimula R6 M 10W-40 in 3 Scania R440 Up to 45% EGR (Euro 5/6) plus high S-Level in fuel high TBN retention is required

2 x ODI 120k km according to Scania long drain field trial protocol

Joint engine inspection after 250.000 km

(4) Scania Long Drain Field Trial





Extremely good condition of the engine

clean grooves to prevent ring sticking






contact pattern




Biofuel leads to viscosity reduction and corrosive wear

(5) Biofuel

General impact

• Burns differently• More gets into oil• Sump Over-fill

Impact on Engine Oil

• Lower viscosity• Wax forms at low temperature• Additives degrade• Acids form

• Less Soot in oil

Performance impact

• Wear!• Pumping problems• Shorter oil life (ODI)• Metal corrosion




0

2

4

6

8

10

12

14

0 10,000 20,000 30,000 40,000 50,000 60,000 70,000 80,000 90,000

Fresh Oil Viscosity: 11,6 mm2 /s

r e c o m m

e n

d e

d o i l d r a i n

-36% VISCOSITY !

Oil Milage [km]

kV@ 100°C[mm2/s]

(5) Biofuel: Viscosity Reduction




Rimula R6 LM/LMEDoubled oil drain interval

Test duration: 500.000 km

(5) Biofuel: Engine Inspection




Operating Window:Recommended ODI:

50,000 kmLimit Fe Wear high:

250 ppm

Oil Milage [km]

Fe[ppm]

(5) Biofuel: Extremely Extended ODI With Rimula R6 LM

0

100

200

300

0 20,000 40,000 60,000 80,000 100,000 120,000 140,000 160,000 180,000 200,000




500.000 km / 3 oil drains in 5 years!!Rimula R6 LM proviced excellent wear protection and cleanliness

(5) Biofuel: Extremely Good Engine Condition




USA: Prototype engine oils with HTHS 2,9 instead of 3,5 (10W-20/30) 16 Mio mls controlled tests, 10 engine inspections @ 500.000 mls

60.000 mls ODI in Volvo, DDC, Paccar, Navistar

High shear rate: nrotor : 3.200 min-1

High temperature: 150°C

Limit as of now: 3,5

(6) Future Low Viscosity Engine Oil Validation

0

25

50

75

100

125

150

175

200

0 20,000 40,000 60,000 80,000 100,000 120,000

I r o

n ,

p p m

Oil Miles

2011/2012 MY DDC DD15

Rotella T TP 15W-40

Rotella T5 10W-30

Rotella T5 10W-30 Low HTHS

Rotor

Lubricant

Cylinder




USA: Prototype engine oils with HTHS 2,9 instead of 3,5 (10W-20/30)16 Mio mls controlled tests, 10 engine inspections @ 500.000 mls

60.000 mls ODI in Volvo, DDC, Paccar, Navistar





HTHS 2,9 Field Trial Scania 2 x 120k km (75k ml) ODI

Engine inspection

Wear pattern similar to HTHS 3,5 viscosity





(7) Pionieering Extended Oil Drain Interval In India

Rimula R6 M 10W-40 in 7 BharatBenz Daimler India introduced first series of trucks in Sept 2012

Presence in all major truck segments from 9 to 49 tones GVW

Rimula R6 M 10W-40 exclusive FFO for Mercedes-Benz India with extended ODI

ODI: 18k km 36k km ODI: 50k km 100k kmODI: 18k km

36k km ODI: 50k km

100k km



Copyright of Shell Global SolutionsEngine Milage [km]

kV100

[mm2/s]

Oil-Milage108.643 km 102.626 km

fresh oil viscosity

S A E 3 0

S A E 4 0


6

7

8

9

10

11

12

13

14

15

16

17

18

100,000 150,000 200,000 250,000 300,000 350,000



Copyright of Shell Global SolutionsEngine Milage [km]

Fe

[ppm]

0

50

100

150

200

250

300

100,000 150,000 200,000 250,000 300,000 350,000


Oil-Milage108.643 km 102.626 km

Fe Limit, „elevated“: 200 pm




Mercedes-Benz`s accelerated prototype test circuit in South Africa Very latest engine technology Euro 6+

Rugged topography, high load and high speed

Severity Factor: 3

(8) Ultimate Proof Of Performance

Extended Oil Drain

South Africa Europe

ODI:

75.000 km 210.000 km

Test period:

500.000 1.500.000 km

Euro 6 engine





Shell Rimula R6 LM/LME in Mercedes-Benz`s

LATEST: Euro 6

LARGEST: 15,6 L

STRONGEST: 625 hp and 3.000 Nm

Avg fuel consumption: 72 L/100 km

Avg monthly milage: 27.000 km

0,5 Mio km in 1,5 years

0,5 Mio km x SF 3 = 1,5 Mio km = MB`s new engine lifetime target

75.000 km ODI x SF 3 = 210.000 km = MB`s new ODI target





Oil temperature mainly between 110-120°C

Frequency

[%]

Oil Temperature [°C]




0

20

40

60

80

100

120

140

160

180

200

220

240

0

5 0 , 0 0 0

1 0 0 , 0 0 0

1 5 0 , 0 0 0

2 0 0 , 0 0 0

2 5 0 , 0 0 0

3 0 0 , 0 0 0

3 5 0 , 0 0 0

4 0 0 , 0 0 0

4 5 0 , 0 0 0

5 0 0 , 0 0 0

94.249 Oil km 76.086 Oil km 75.386 Oil km 74.987 Oil km 75.986 Oil km 76.826 Oil km

Al,

Fe,

Cu,

Pb,

Cr

Si

[ppm]


500 250.000 500.000

Engine Milage [km]




Joint engine inspection at Mercedes-Benz`s Global R&D Center





Shell Rimula R6 LM/LME demonstrated superior protection andcleanliness in Daimler`s latest engine generation





Quiz Quiz Quiz Quiz Quiz Quiz Quiz Quiz Quiz Quiz

Question:

What is the severity factor in South Africa?




(9) EATS Compatibility: Ash Loading/DPF Clogging

Ash leads to increased back pressure and maintenance cost




0

50

100

150

200

250

300

0

5 0

, 0 0 0

1 0

0 , 0 0 0

1 5

0 , 0 0 0

2 0

0 , 0 0 0

2 5

0 , 0 0 0

3 0

0 , 0 0 0

3 5

0 , 0 0 0

4 0

0 , 0 0 0

DPF Milage[km]

Backpressure[mbar]

conventional oil 15W-40Rimula R6 LM 10W-40


200.000 400.000

4 city buses, Euro 3 OM 906 engine, 5 years

Backpressure over DPF and ash mass in DPF

Doubling of cleaning interval with Rimula R6 LM

b l h d / l




Ash mass in DPFDPF milage: 225.000 km

Oil consumption: 0,3 L / 1.000 km

Rimula R6 LM Conventional

Ash Mass: 0,53 kg 1,21kg


l l




(10) Fuel Economy in Volvo Euro 5

2.00%

1.37%

1.59%

1.91%

3.57%

2.51%

2.88%

3.18%

0.0%

0.5%

1.0%

1.5%

2.0%

2.5%

3.0%

3.5%

4.0%

4.5%

5.0%

SORT Cold SORT HOT SORT AVG Highway

% F

E B e n e f i t v s .

B a s e l i n e

Top-Tier

Experimental

Error bars: 95% Confidence Intervals

4x identical Volvo FH12D13C Euro 5 engine, 460 hp

( ) l ld l




(11) Fuel Economy Field Trial In TATA BS III Engines

Shell Rimula T5 E 10W-30 Vehicles: 4 x TATA vehicles BS III

Test Oils: 15W-40 vs 10W-30

Duration: 6.000 - 10.000 km each vehicle

( ) l ld l A A S





Shell Rimula T5 E 10W-30 Swapping test oils several times

Each period ~ 1.200 km

Fuel Consumption [L/100 km]

15W-40 vs 10W-30

5.2

5.3

5.4

5.5

5.6

5.7

5.8

5.9

6

Sept Oct Nov Dec Jan Feb Mar

[L/100 Km] [Km/L]

15W-40 10W-30 15W-40 10W-30

16

17

18

19

20

21

22

period 1 period 2 period 3 period 4 period 5 period 6 period 7

(11) F l E Fi ld T i l I TATA BS III E i





Shell Rimula T5 E 10W-30 Swapping test oils several times

Each period ~ 1.200 km

Fuel Consumption [L/100 km]

15W-40 vs 10W-30

5.2

5.3

5.4

5.5

5.6

5.7

5.8

5.9

6

Sept Oct Nov Dec Jan Feb Mar

[L/100 Km] [Km/L]

3%+ FEcompared to 15W-40

15W-40 10W-30 15W-40 10W-30

16

17

18

19

20

21

22

period 1 period 2 period 3 period 4 period 5 period 6 period 7

F l I Th 2 d L C Bl k




Fuel Is The 2nd Largest Cost Block

´FE calculation xls sheet

F l E C l l i C F l C




Fuel Economy Calculation: Current Fuel Cost

Average Fuel Consumption: L/100km 34

Annual Vehicle Milage: km 130.000

Annual Fuel Demand: L/vehicle 44.200

Fuel Price: €/L 1,00Annual Fuel Costs: $/vehicle $44.200

Fuel Economy: % 0,50

Less Fuel Cost: $/vehicle $221

Oil Sump Volume: L 40

15W-40 Oil Price: $/L 1,20

Number Of Oil Drains Per Year: 2,0

Annual Oil Demand Per Year: L//vehicle 80

Annual Oil Cost Per Year: $/vehicle 96

5W-30 Oil Price: $/L 3,00

Number Of Oil Drains Per Year: 1,0 Annual Oil Demand Per Year: L/ vehicle 40


Higher Oil Cost: $/vehci le -24

Annual Saving Per Vehicle: $/vehicle $197

Number vehicles: 100Total Annual Saving: $/fleet $19.700

F l E C l l i F l S i




Fuel Economy Calculation: Fuel Saving








15W-40 Oil Price: $/L 1,20










FE benefit withRimula R6 LME 5W-30

F l E C l l ti Additi l Oil C t




Fuel Economy Calculation: Additional Oil Cost








15W-40 Oil Price: $/L 1,20











Extended ODI withRimula R6 LME 5W-30

F l E C l l ti B tt Li




Fuel Economy Calculation: Bottom Line








15W-40 Oil Price: $/L 1,20










Without labour cost,downtime etc


Extended ODI withRimula R6 LME 5W-30

Fi ld T i l




Field Trials

Key Element of R&D activities and customer supportCustomers want PROOF and no promises wrt performance and benefits

Real World operating conditions give best proof of performance

>500 vehicles every day in the year in tests worldwide, and we will continue

heavy duty engine oils-field trials

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