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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
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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
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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
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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
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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
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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
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(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
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(2) Engine Cleanliness And Extended ODI
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
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Extremely low wear rates
0
100
200
300
0 100 200 300 400 500 600
Operating Window:Recommended ODI: 250 hrs
Limit Fe Wear high: 250 ppm
(2) Engine Cleanliness And Extended ODI
Oil Milage [hrs]
Fe
[ppm]
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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
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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
(3) Soot Handling Capability
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
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Air compressor discharge pipes: same application but different oil
(3) Soot Handling Capability
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
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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
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(4) Scania Long Drain Field Trial
Extremely low wear rates
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(4) Scania Long Drain Field Trial
Extremely good condition of the engine
clean grooves to prevent ring sticking
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(4) Scania Long Drain Field Trial
Extremely good condition of the engine
contact pattern
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(4) Scania Long Drain Field Trial
Extremely good condition of the engine
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(4) Scania Long Drain Field Trial
Extremely good condition of the engine
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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
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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
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Rimula R6 LM/LMEDoubled oil drain interval
Test duration: 500.000 km
(5) Biofuel: Engine Inspection
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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
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500.000 km / 3 oil drains in 5 years!!Rimula R6 LM proviced excellent wear protection and cleanliness
(5) Biofuel: Extremely Good Engine Condition
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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
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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
(6) Future Low Viscosity Engine Oil Validation
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HTHS 2,9 Field Trial Scania 2 x 120k km (75k ml) ODI
Engine inspection
Wear pattern similar to HTHS 3,5 viscosity
(6) Future Low Viscosity Engine Oil Validation
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(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
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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
(7) Pionieering Extended Oil Drain Interval In India
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
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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
(7) Pionieering Extended Oil Drain Interval In India
Oil-Milage108.643 km 102.626 km
Fe Limit, „elevated“: 200 pm
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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
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(8) Ultimate Proof Of Performance
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
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(8) Ultimate Proof Of Performance
Oil temperature mainly between 110-120°C
Frequency
[%]
Oil Temperature [°C]
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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]
(8) Ultimate Proof Of Performance
500 250.000 500.000
Engine Milage [km]
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Joint engine inspection at Mercedes-Benz`s Global R&D Center
(8) Ultimate Proof Of Performance
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Shell Rimula R6 LM/LME demonstrated superior protection andcleanliness in Daimler`s latest engine generation
(8) Ultimate Proof Of Performance
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(8) Ultimate Proof Of Performance
Shell Rimula R6 LM/LME demonstrated superior protection andcleanliness in Daimler`s latest engine generation
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Quiz Quiz Quiz Quiz Quiz Quiz Quiz Quiz Quiz Quiz
Question:
What is the severity factor in South Africa?
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(9) EATS Compatibility: Ash Loading/DPF Clogging
Ash leads to increased back pressure and maintenance cost
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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
(9) EATS Compatibility: Ash Loading/DPF Clogging
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
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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
(9) EATS Compatibility: Ash Loading/DPF Clogging
l l
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(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
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(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
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(11) Fuel Economy Field Trial In TATA BS III Engines
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
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(11) Fuel Economy Field Trial In TATA BS III Engines
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
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Fuel Is The 2nd Largest Cost Block
´FE calculation xls sheet
F l E C l l i C F l C
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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
Annual Oil Cost Per Year: $/vehicle 120
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
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Fuel Economy Calculation: Fuel Saving
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: % 1,50
Less Fuel Cost: $/vehicle $663
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
Annual Oil Cost Per Year: $/vehicle 120
Higher Oil Cost: $/vehci le -24
Annual Saving Per Vehicle: $/vehicle $639
Number vehicles: 100Total Annual Saving: $/fleet $63.900
FE benefit withRimula R6 LME 5W-30
F l E C l l ti Additi l Oil C t
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Fuel Economy Calculation: Additional Oil 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: % 1,50
Less Fuel Cost: $/vehicle $663
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
Annual Oil Cost Per Year: $/vehicle 120
Higher Oil Cost: $/vehci le -24
Annual Saving Per Vehicle: $/vehicle $639
Number vehicles: 100Total Annual Saving: $/fleet $63.900
FE benefit withRimula R6 LME 5W-30
Extended ODI withRimula R6 LME 5W-30
F l E C l l ti B tt Li
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Fuel Economy Calculation: Bottom Line
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: % 1,50
Less Fuel Cost: $/vehicle $663
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
Annual Oil Cost Per Year: $/vehicle 120
Higher Oil Cost: $/vehci le -24
Annual Saving Per Vehicle: $/vehicle $639
Number vehicles: 100Total Annual Saving: $/fleet $63.900
Without labour cost,downtime etc
FE benefit withRimula R6 LME 5W-30
Extended ODI withRimula R6 LME 5W-30
Fi ld T i l
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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
Recommended