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2011 - 12LOCATION UNIT ENG NO. CONCERN PERSON MR. USMAN AMJAD, MANAGER POWER
NAUBAHAR BOTTLING 38 S.I Estate, Gujranwala UNIT # 02 ENG # 01 0333-8229887 ; 055-6440072
( PEPSI INTERNATIONAL ) SENIOR MANAGEMENT MR.JUNAID AHSAN , MANAGER PLANT 2
0333-8229987 ; 055-6440072
ENGINE DETAIL MR.ATIQ BALOCH, GENERAL MANAGER PLANTS
MAKE CUMMINS, USA 0333-8229993 ; 055-3253601MODEL QST 30 (worked 8000 hrs)
MFG YEAR FIRST TRIAL COSTING ON; 500 HRS SECOND TRIAL COSTING ON; 700 HRS THIRD TRIAL COSTING ON; 760 HRSRATED POWER 800 kWe (1000 kVA) COST of OIL CHANGE COST of OIL CHANGE COST of OIL CHANGERPM/ BURN TYPE 1500 / RICH OIL UNIT COST, RS/L 292.00 OIL UNIT COST, RS/L 292.00 OIL UNIT COST, RS/L 292.00FUEL Diesel PER OIL CHANGE COST 43,800 PER OIL CHANGE COST 43,800 PER OIL CHANGE COST 43,800AIR INTAKE NATURAL ASPIRATED ANNUAL OIL CHANGE COST 383,688 ANNUAL OIL CHANGE COST 383,688 ANNUAL OIL CHANGE COST 383,688
LUBE OIL COST of ON-LINE FILTERS COST of ON-LINE FILTERS COST of ON-LINE FILTERSOIL MNFG / BRAND TOTAL Rubia TIR 7400 PER CHANGE LINE FILTER COST 46,500 PER CHANGE LINE FILTER COST 46,500 PER CHANGE LINE FILTER COST 46,500TBN NEW OIL 10.3 mg KOH/g (Lube oil 4 line filters + 2 fuel filt.) (Lube oil 4 line filters + 2 fuel filt.) (Lube oil 4 line filters + 2 fuel filt.)TBN LIMIT 5.00 - 5.15 mg KOH/g ANNUAL FILTER COST 407,340 ANNUAL FILTER COST 407,340 ANNUAL FILTER COST 407,340SUMP CAPACITY, LMAKE UP, L/WEEK 10 COST of BY-PASS FILTERS 13000 COST of BY-PASS FILTERS 13000 COST of BY-PASS FILTERS 13000DRAIN INTERVAL, HRS ( APPROX. IN ONE MONTH) OIL LIFE EXTENDED, HRS 250 OIL LIFE EXTENDED, HRS 450 OIL LIFE EXTENDED, HRS 510OIL CHANGES / YR ( FROM PAYBACK: engine working hrs 2190 / year.) ( 500 hrs - 250 hrs) ( 700 hrs - 250 hrs) ( 760 hrs - 250 hrs)
TOTAL ANNUAL COST (RS/YR) ( incl. on-line filters and oil ) OIL CHANGE /YR 4.4 OIL CHANGE /YR 3.1 OIL CHANGE /YR 2.9
(Av. every 1.4 month, oil change interval) (Av. every 1.4 month, oil change interval) (Av. every 1.4 month, oil change interval)KLEENOIL BY-PASS SYSTEM INSTALLED*BY-PASS MODEL SDU-M8 *FROM ENGINE OUTLET LINE FILTER SUPPLY OIL COST RS/YR 191,844 OIL COST RS/YR 137,031 OIL COST RS/YR 126,213*BY-PASSES INSTALLED 02 NOS *TO ENGINE INLET OIL SUMP/ No psi K.FILTER by-pass COST RS /YR 227,760 K.FILTER by-pass COST RS /YR 227,760 K.FILTER by-pass COST RS /YR 227,760
ENG FILTER on-line COST RS /YR 203,670 ENG FILTER on-line COST RS /YR 145,479 ENG FILTER on-line COST RS /YR 133,993
1) ONE OIL LIFE EXTENSION DATE RUNNING FILTER SDFC SDFC CURRENT TOTAL COST WITH KLEENOIL, RS/YR 623,274 TOTAL COST WITH KLEENOIL, RS/YR 510,270 TOTAL COST WITH KLEENOIL, RS/YR 487,967HRS LIFE UNITS COST Rs. LIFE
KLEENOIL MICROFILTRATIONBY-PASS ON DIESEL ENGINES
PROJECT REPORT
CUSTOMER
2011
150
250
791,028
9194.6
8.8
TILL, JUNE 18, 2012 TILL, OCT. 04, 2012
1) ONE OIL LIFE EXTENSION DATE RUNNING FILTER SDFC SDFC CURRENT TOTAL COST WITH KLEENOIL, RS/YR 623,274 TOTAL COST WITH KLEENOIL, RS/YR 510,270 TOTAL COST WITH KLEENOIL, RS/YR 487,967HRS LIFE UNITS COST Rs. LIFE
OIL CHANG DATE AUG 08, .2011 oil change TOTAL COST WITHOUT KLEENOIL, RS/YR 791,028 TOTAL COST WITHOUT KLEENOIL, RS/YR 791,028 TOTAL COST WITHOUT KLEENOIL, RS/YR 791,028BY-PASS INSTALLED AUG 08, .2012 0 inst.
1 CARTRIDGE CHANGE SEPT 30, 2011 250 2 26000 achieved ANNUAL SAVINGS, Rs. ANNUAL SAVINGS, Rs. ANNUAL SAVINGS, Rs.2 CARTRIDGE CHANGE MAR 03, 2012 250 2 26000 achieved
500 4 52000 ( 1 US $ = 92 Rs.) US$ 1,823 ( 1 US $ = 94 Rs.) US$ 2,987 ( 1 US $ = 96 Rs.) US$ 3,157
2) Extra 450 hrs or 1.80 spans ; OIL LIFE EXTENSION ( Trial on 2nd oil change) OTHER BENEFITS OTHER BENEFITS OTHER BENEFITS
OIL CHANG DATE APR. 03, 2012 0 oil change
1 CARTRIDGE CHANGE APR. 22, 2012 250 2 26000 achieved LESS CONTAMINATION IN ENGINE OIL>> LESS WEAR LESS CONTAMINATION IN ENGINE OIL>> LESS WEAR LESS CONTAMINATION IN ENGINE OIL>> LESS WEAR
2 CARTRIDGE CHANGE MAY 27, 2012 250 2 26000 achieved EXTENDED TOP END OVERHAULING EXTENDED TOP END OVERHAULING EXTENDED TOP END OVERHAULING3 CARTRIDGE CHANGE JUNE 18, 2012 200 2 26000 achieved EXTENDED MAJOR OVERHAULING EXTENDED MAJOR OVERHAULING EXTENDED MAJOR OVERHAULING
700 6 78000 LESS BREAKDOWNS FOR OIL CHANGE AND MANINTENANCE LESS BREAKDOWNS FOR OIL CHANGE AND MANINTENANCE LESS BREAKDOWNS FOR OIL CHANGE AND MANINTENANCE
2) Extra 510 hrs or 2.04 spans ; OIL LIFE EXTENSION ( Trial on 3rd oil change)OIL CHANG DATE JUNE 18, 2012 0 oil change
1 CARTRIDGE CHANGE JULY 25, 2012 250 2 26000 achieved2 CARTRIDGE CHANGE AUG. 30, 2012 250 2 26000 achieved3 CARTRIDGE CHANGE OCT. 04, 2012 260 2 26000 achieved
760 6 78000
TOTAL HRS
9944.6
9194.6
9194.6
280,758
10194.610394.6
TOTAL HRS
9694.6
9444.6 167,7549694.6
10394.610644.610894.611154.6
TOTAL HRS
303,061
ENGINE CUMMINS 800 KW DIESEL ENGINE OIL BRAND : TOTAL Rubia TIR 7400 15W40
Test Method D2896 D445 D2270 Crackle AAS AAS AAS AAS AAS
Working TBN Viscosity 100 c.St Viscosity Index Water ppm Oil change & Inspt. REMARKS
Hours (V) (VI) Water %age Si Fe Cu Cr Pb Dates
New Oil: 10.30 14.2 142 < 0.02% = 200 ppm < 5 < 5 < 5 < 5 < 5 New oil properties
End Limit: 250 hrs 5.15.
+/- 20% 100 < 0.2% = 2000 ppm < 40 < 40 < 40 < 40 < 40 Last acceptable limit
Start-up without Kleenoil - Actual Status
250 hrs 6.72 11.45 131 < 0.2% (negative) < 4 < 31 < 9 < 2 < 7 Jun. 2011 End limit
250 hrs 6.63 11.58 130 < 0.2% (negative) < 3 < 29 < 6 < 1 < 2 Aug. 2011 End limit
Start-up with Kleenoil - Actual Status / Date of new oil, line filters and Kleenoil filter replacement 08- Aug. 2011
125 hrs 9.12 14.05 141 < 0.2% (negative) < 1 < 7 < 2 < 1 < 1 14- Sept. 2011V is slightly reduced due tophenomen of fuel dilution
Wear Metal ppm
NOTEIn diesel fuel there is moisture > 1% as compare to Petrol & Natural gas < 1%., so due to fuel dilution phenomenon viscosity is reduced at primary phase while on the other hand higher oxidation rate leads to
Nox, Sox --> acid formation, thus reacting with KOH (TBN of oil) and forming solid and moisture.In secondary phase solid contaminants and soot particles (carbons) leads to increase in viscosity, so finally viscosity looks stable but chemically there is TBN drop up to 50% in 250 hrs and increase of
contaminants, the major indication of oil change.
KLEENOIL MICROFILTRATIONContinuous filtration simply lead to removal of moisture up to 150 ppm and solid contaminants up to 1 micrometer, thus removal of physical changes at initial phase prevents the formation of chemical changes
which are going take place in second phase.It is important to have consistent engine working to prevent stagnant oil depletion, so if all closed sumps are periodically cleaned daily with filtration rig/ by-pass ( 2 hrs daily minimum), oil will retain its
properties, if not in use.
CUMMINS: 500 HRS. ; 700 HRS. ; 760 HRS. CASE STUDY ON LAB REPORTS
125 hrs 9.12 14.05 141 < 0.2% (negative) < 1 < 7 < 2 < 1 < 1 14- Sept. 2011V is slightly reduced due tophenomen of fuel dilution
250 hrs 8.23 13.93 139 < 0.2% (negative) < 2 < 9 < 3 < 1 < 1 30- Sept. 2011 This must be actual oil life
Due to WAPDA available for 24 hrs, engine was shut down for 2 months and another month for maintenance and low production load (winter has just ended) SHUTDOWN
350 hrs 7.59 13.54 137 < 0.2% (negative) < 2 < 10 < 3 < 1 < 1 30- Jan. 2012Due to excess Nox, Sox, oil has
acidic tendency
500 hrs 6.92 13.79 139 < 0.2% (negative) < 6 < 22 < 14 < 2 < 5 21- Mar. 2012Rise in viscosity due to cont. &
soot particles
REMARKS (Diagnosis) : Oil appears to be in satisfactory condition and fit for further use.WAPDA availabe for 24 hrs,
engine SHUTDOWN for 13 days
Date of new oil, line filters and Kleenoil filter replacement 03- April. 2012
290 hrs…. 7.83 14.43 140 < 0.2% (negative) < 4 < 17 < 35 < 3 < 4 27- April. 2012 Oil is fit for further use
470 hrs…. 6.31 15.2 138 < 0.2% (negative) < 6 < 27 < 40 < 4 < 4 22- May. 2012Oil is fit for use only Copper
content slightly increased
700 hrs…. 5.93 15.6 138 < 0.2% (negative) < 11 < 29 < 120 < 6 < 8 18- June. 2012Excessive copper ppm, due to
coating Cu++ part issue.
REMARKS (Diagnosis) : Reason for oil change is excessive copper content, while TBN is within limit for further use.
Date of new oil, line filters and Kleenoil filter replacement 18- June. 2012
500 hrs…. 6.01 15.65 140 < 0.2% (negative) < 8 < 18 < 42 < 1 < 1 30- Aug. 2012Cu++ ppm is acceptable and oil is
fit for further use
760 hrs…. 5.60 16.05 137 < 0.2% (negative) < 9 < 20 < 45 < 1 < 1 04- Oct. 2012Cu++ ppm is nearly acceptablebut TBN is near to end limit.760 hrs…. 5.60 16.05 137 < 0.2% (negative) < 9 < 20 < 45 < 1 < 1 04- Oct. 2012
Cu++ ppm is nearly acceptablebut TBN is near to end limit.
REMARKS (Diagnosis) : Reason for oil change is copper content slightly increased while TBN is still within limit.Considering TBN, current oil can
be used upto 800 hrs.
Customer: Customer:Fax: Fax:Product Name & Grade: Product Name & Grade:Equipment: Equipment:Model: Model:
Total Equip Running Hours: Total Equip Running Hours:
Oil Top Up Volume: Oil Top Up Volume:Type of Fuel Used: Used Oil: x Fresh Oil: Type of Fuel Used: Used Oil: x Fresh Oil:
Initiated By: Initiated By:
Date: Date:
Properties Properties
Appearance Visual Black Liquid Appearance Visual Black LiquidColour ASTM D1500 Colour ASTM D1500
R.D. at 15 °C D1298 R.D. at 15 °C D1298
Kinematic Viscosity at 40°C, cSt. D445 122.6 Kinematic Viscosity at 40°C, cSt. D445 117.6
Physical properties Physical properties
TEST RESULTS TEST RESULTSTest Method Test Method
Receiving Date/ Time: 10/10/2012 Receiving Date/ Time: 3/9/2012
Diesel Diesel
Reason for Testing: Reason for Testing:
Muhammad Raza Sample No By Lab: CS0786-12 (760) Muhammad Raza Sample No By Lab: CS0786-12 (500)
10 Ltrs Date of Sampling: 10/4/2012 10 Ltrs Date of Sampling: 30/08/2012
Oil Running Hours: 760 Oil Running Hours: 500
QST30-G4 Serial No: (A) QST30-G4 Serial No: (A)Diesel Generator Make: Cummins Diesel Generator Make: Cummins
Phone: Phone:Rubia TIR 7400 Batch Number: Rubia TIR 7400 Batch Number:
TRIAL NO. 3, LAB RESULTS UPTO - 760 HRS
TOTAL OIL PAKISTAN (PVT) LTD.Formerly, Total Atlas Lubricants Pakistan (Pvt.) Ltd.
TOTAL OIL PAKISTAN (PVT) LTD.Formerly, Total Atlas Lubricants Pakistan (Pvt.) Ltd.
Sample Testing Performa Sample Testing Performa
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Naubahar Bottling , Gujranwala
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Naubahar Bottling , Gujranwala
Kinematic Viscosity at 40°C, cSt. D445 122.6 Kinematic Viscosity at 40°C, cSt. D445 117.6Kinematic Viscosity at 100°C, cSt. D445 16.05 Kinematic Viscosity at 100°C, cSt. D445 15.65Viscosity Index D2270 137 Viscosity Index D2270 140Flash Point COC °C D92 Flash Point COC °C D92
Pour Point °C D97 Pour Point °C D97
Ca Content ppm AAS Ca Content ppm AAS
Zn Content ppm AAS Zn Content ppm AAS
P Content ppm AAS P Content ppm AAS
Water Crackle -ve Water Crackle -ve
Si Content ppm AAS 9 Si Content ppm AAS 8
Fe Content ppm AAS 20 Fe Content ppm AAS 18Cu Content ppm AAS 45 Cu Content ppm AAS 42Cr Content ppm AAS 1 Cr Content ppm AAS 1Pb Content ppm AAS 1 Pb Content ppm AAS 1
Total Acid No. mgKOH/g. D974 Total Acid No. mgKOH/g. D974
Total Base No. mgKOH/g. D2896 5.60 Total Base No. mgKOH/g. D2896 6.01Oxidation A/cm IR 1959 / 2132 Oxidation A/cm IR 1959 / 2132
Nitration A/cm IR 1959 / 2132 Nitration A/cm IR 1959 / 2132
Diagnosis: Oil appear to be in satisfactory condition & fit for further use.except copper Diagnosis: Oil appear to be in satisfactory condition & fit for further use.except copper
Content cross the limits Content cross the limitsAction: Please follow your OEM's recommendations Action: Please follow your OEM's recommendations
This is an electronically generated report and does not require signatures. This is an electronically generated report and does not require signatures.
Reviewed By:Technical Consultant Approved by: Technical Manager Reviewed By:Technical Consultant Approved by: Technical Manager
Results represent the testing performed on the sample drawn by the customer and does not guarantee the bulk. Results represent the testing performed on the sample drawn by the customer and does not guarantee the bulk.
Chemical properties Chemical properties
Wear Metals Wear Metals
Contaminants Contaminants
Additive content Additive content
3rd Floor, Bahria Comples II, M.T. Khan Road, Karachi, Pakistan. 3rd Floor, Bahria Comples II, M.T. Khan Road, Karachi, Pakistan.
UAN: (92-21) 111-000-825 Fax: (92-21) 561 0078 UAN: (92-21) 111-000-825 Fax: (92-21) 561 0078
This is an electronically generated report and does not require signatures. This is an electronically generated report and does not require signatures.
TOTAL ATLAS LUBRICANTS PAKISTAN (PVT) LTD.
Customer: Customer:Fax: Fax:Product Name & Grade: Product Name & Grade:Equipment: Equipment:Model: Model:
Total Equip Running Hours: Total Equip Running Hours:
Oil Top Up Volume: Oil Top Up Volume:Type of Fuel Used: Used Oil: yes Fresh Oil: Type of Fuel Used: Used Oil: yes Fresh Oil:
Initiated By: Initiated By:Date: Date:
Properties Properties
Appearance Visual Black Liquid Appearance Visual Black LiquidColour ASTM D1500 Colour ASTM D1500
R.D. at 15 °C D1298 R.D. at 15 °C D1298
Physical properties Physical properties
TEST RESULTS TEST RESULTSTest Method Test Method
19/06/2012 Receiving Date/ Time: 14/06/2012 23/05/2012 Receiving Date/ Time: 24/05/2012
Diesel Diesel EngineReason for Testing: Reason for Testing:
Muhammad Raza Sample No By Lab: CS0547-12 Muhammad Raza Sample No By Lab: CS0449-12
10 Liters per week Date of Sampling: 18/06/2012 10 Ltrs/week Date of Sampling: 22/05/2012
Oil Running Hours: 700 Oil Running Hours: 470
Serial No: QST30 G4 Serial No: QST30 G4Diesel Generator Make: Cummins Diesel Engine Make: Cummins
Phone:Rubia TIR 7400 Batch Number: Rubia TIR 7400 Batch Number:
Sample Testing Performa Sample Testing Performa
To b
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Naubahar Bottling Co, Gujranwala
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Naubahar Bottling Co GujranwalaPhone:
TRIAL NO. 2, LAB RESULTS UPTO - 700 HRS
TOTAL OIL PAKISTAN (PVT) LTD.Formerly, Total Atlas Lubricants Pakistan (Pvt.) Ltd.
R.D. at 15 °C D1298 R.D. at 15 °C D1298
Kinematic Viscosity at 40°C, cSt. D445 118.7 Kinematic Viscosity at 40°C, cSt. D445 113.0Kinematic Viscosity at 100°C, cSt. D445 15.60 Kinematic Viscosity at 100°C, cSt. D445 15.02Viscosity Index D2270 138 Viscosity Index D2270 138Flash Point PMCC °C D93 Flash Point COC °C D92
Pour Point °C D97 Pour Point °C D97
Ca Content ppm AAS Ca Content ppm AAS
Zn Content ppm AAS Zn Content ppm AAS
P Content ppm AAS P Content ppm AAS
Water Crackle -ve Water Crackle -veSi Content ppm AAS 11 Si Content ppm AAS 6
Fe Content ppm AAS 29 Fe Content ppm AAS 27Cu Content ppm AAS 120 Cu Content ppm AAS 40Cr Content ppm AAS 6 Cr Content ppm AAS 4Pb Content ppm AAS 8 Pb Content ppm AAS 4
Total Acid No. mgKOH/g. Total Acid No. mgKOH/g. D974
Total Base No. mgKOH/g. D2896 5.93 Total Base No. mgKOH/g. D2896 6.31Oxidation A/cm IR 1959 / 2132 Oxidation A/cm IR 1959 / 2132
Nitration A/cm IR 1959 / 2132 Nitration A/cm IR 1959 / 2132
Diagnosis: Diagnosis: Oil appear to be in satisfactory condition except copper content which hascrossed condemning limit
Action: Action: Please check bearings & bushes of your machine
This is an electronically generated report and does not require signature3rd Floor, Bahria Comples II, M.T. Khan Road, Karachi, Pakistan. 3rd Floor, Bahria Comples II, M.T. Khan Road, Karachi, Pakistan.
UAN: (92-21) 111-000-825 Fax: (92-21) 561 0078 UAN: (92-21) 111-000-825 Fax: (92-21) 561 0078
Reviewed By:Technical Consultant Approved by: Technical Manager
Reviewed By:Technical Consultant Approved by: Technical Manager This is an electronically generated report and does not require signatures.
The copper content is very high. please check the bearings.
Recommend to change the oil.
Results represent the testing performed on the sample drawn by the customer and does not guarantee the bulk. Results represent the testing performed on the sample drawn by the customer and does not guarantee the bulk.
Chemical properties Chemical properties
Wear Metals Wear Metals
Contaminants Contaminants
Additive content Additive content
Customer:Fax:Product Name & Grade:Equipment:Model:
Total Equip Running Hours:
Oil Top Up Volume:Type of Fuel Used: Used Oil: yes Fresh Oil:
Initiated By:Date:
Properties
Appearance Visual Black LiquidColour ASTM D1500
R.D. at 15 °C D1298
Kinematic Viscosity at 40°C, cSt. D445 110.0Kinematic Viscosity at 100°C, cSt. D445 14.43
TEST RESULTSTest Method
Physical properties
Diesel EngineReason for Testing:
Muhammad Raza Sample No By Lab: CS0340-12Receiving Date/ Time: 29/04/2012
Oil Running Hours: 290
10 Ltrs/week Date of Sampling: 27/04/2012
Diesel Engine Make: CumminsSerial No: QST30 G4
NEW OIL MSDS
TOTAL OIL PAKISTAN (PVT) LTD.
Sample Testing Performa
To b
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by t
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Naubahar Bottling Co GujranwalaPhone:
Rubia TIR 7400 Batch Number:
Kinematic Viscosity at 100°C, cSt. D445 14.43Viscosity Index D2270 140Flash Point COC °C D92
Pour Point °C D97
Ca Content ppm AAS
Zn Content ppm AAS
P Content ppm AAS
Water Crackle -veSi Content ppm AAS 4
Fe Content ppm AAS 17Cu Content ppm AAS 35Cr Content ppm AAS 3Pb Content ppm AAS 4
Total Acid No. mgKOH/g. D974
Total Base No. mgKOH/g. D2896 7.83Oxidation A/cm IR 1959 / 2132
Nitration A/cm IR 1959 / 2132
Diagnosis: Sample is fit for further use
Action: Please follow your OEM recommandations for oil change
3rd Floor, Bahria Comples II, M.T. Khan Road, Karachi, Pakistan.
UAN: (92-21) 111-000-825 Fax: (92-21) 561 0078
This is an electronically generated report and does not require signatures.
Results represent the testing performed on the sample drawn by the customer and does not guarantee the bulk.
Reviewed By:Technical Consultant Approved by: Technical Manager
Chemical properties
Wear Metals
Contaminants
Additive content