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InfineumInsight.com/Learn
Field testing
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Performance you can rely on.
Topics
• Why run field trials
• Heavy Duty & Passenger Car Field Trial Overview
• Field Trial Overview
• Field Trial Execution
– pre-trial & during trial
– post-trial
• Component rating (pass/fail, good/bad) examples
• Oil condition & analysis
– degradation & trending
• Summary
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Why run Field Trials
Formal OEM Approvals
• Some OEMs only approve oils by field testing
• Others require field test data to support read across
Development or Evaluation
• New Additive Packages or components
• Unconventional Base Stocks
• Unconventional fuels
• Alternative viscosity grades
• Extended Oil Drain Intervals
• New Engine Hardware
• Comparative evaluation
vs. fired engine or bench tests
Demonstration of performance and Marketing
• Further validation of performance following static engine and laboratory tests
• Proof of performance
• No harm testing
• Generation of marketing data
• Fuel Economy demonstrations
Field Trials run by Infineum are initiated by internal programmes, OEM’s or customers requirements.
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Why run Field Trials
Less representative of in-service performance
Increasing cost and time to acquire data
Bench Tests – Rig Tests – Engine Tests – Field Trials – End Application
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Why run Field Trials.
• OEMs require field tests to ensure oil quality remains appropriate for
• Increased demand on oil
• Hardware changes and additions
• Field tests give them high confidence because the tests are carried out in realistic end-user conditions.
• Increasing stress on oil:
• extended oil drain intervals
• smaller sump sizes
• higher engine outputs
• stricter emission legislation
• Fuel economy oils
• Some HD OEM’s operate a finished lubricant based approval system.
• Others only require field trials after significant lubricant formulation changes.
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Typical field trial (Overview) Heavy Duty & Passenger Car Motor Oil
HD PCMO
Vehicles per candidate 3 3
Field trial length 300,000 km 100,000 km
Oil drain interval 100,000 km 15,000 km
Used oil sampling frequency 25,000 km 5,000 km
Drive cycle Long Haul (44-60 T) 20% urban, 80% motorway
Vehicle source Fleet operator vehicles Purchased vehicles
Mileage accumulation Fleet owner drivers Fleet owner drivers
Contract drivers
Time to complete 18-24 months 4-12 months
EOT engine strip and rebuild OEM approved Workshops Contract workshops
Participation at EOT engine
inspection
Infineum, OEMs & Independent
accredited raters
Infineum & Independent
accredited raters
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Typical field trial (Overview)
• OEM’s specify or endorse proposals for:
• Vehicle and engine type
• Overall test distance and oil drain interval
• Drive cycles, routes and engine severity
• During the field trial, oil samples are periodically taken and analysed:
• To ensure oil quality is maintained during oil drain intervals
• To ensure there are no problems with the engine
• At the end of the field trial, engines are stripped:
• Pistons are rated for carbon deposits
• Bearings, liners and valve train are rated for wear
• Oil sump, covers and components are rated for general cleanliness
• Other components are also rated
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Field Trial Execution Process and Control
Pre-Trial and during Trial
Clearly defined and understood procedures are key:
• Flush cycle prior to Start of Test (SOT)
• Oil and filter changes at SOT
• Oil sampling according to the test plan
• Sampling equipment, technique, & labelling, are all important considerations
• Oil changes according to the test plan
• Steps to avoid lubrication mistakes
• Accurate record keeping
• Oil consumption
• Fuel consumption
• Unusual service events
• Deviations from plan
• Continuous, honest and open communication
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Field Trial Execution Process and Control
Post-Trial
Clearly defined engine strip down procedure prior to inspection:
• Number and lay out components according to their cylinder position
• Pistons, with piston rings still in place
• Oil Sump and Cylinder Head Cover(s) inverted and allowed to drain
• Valve train gear dismantled
• Valves removed from Cylinder Heads
• Crankshaft & Camshaft made accessible
• Main and Con-rod Bearing shells removed
• Cylinder Liners removed
• Turbo Charger, & Oil Mist Separator removed & dismantled
• Oil pump opened
• Other parts as required by OEMs are also inspected
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Engine dismantled for inspection
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End of Trial Engine inspection
• Pistons (deposits)
• 1st & 2nd Grooves.
• Land(s)
• Piston Rings (ring stick, wear, deposits, pitting)
• Top Ring
• 2nd Ring
• Oil Control Ring
• Liners/Bores (wear, gloss, polish, lacquer, corrosion)
• Ring Reversal
• Swept Area
• Bearings, Bushes & Journals (wear, pitting)
• Crankshaft
• Camshaft (lobes)
• Gudgeon pins
• Main Bearings
• Con-rod (big end) bearings
• Small end bushes
• Engine Cleanliness (deposits, sludge)
• Sump
• Engine Block
• Covers
• Valve Train (wear)
• Cam Followers
• Pushrods
• Rocker bushes
• Rocker pads
• Valve bridges
• Valves & Head (wear, deposits)
• Inlet valve & port deposits
• Valve faces & Seats
• Valve stems & valve guides
• Other
• Turbo (deposits)
• Thrust bearings (wear)
• Filtration systems (cleanliness, deposits, sludge)
Components from each vehicle is inspected, rated and photographed.
Ratings, photos and used oil analysis data from all vehicles are compiled into a final field trial report.
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Pistons Merit ratings
50.9 Merit Rating. 13.7 Merit Rating.
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Pistons Merit ratings
50.9 Merit Rating
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Pistons Merit ratings
13.7 Merit Rating
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Piston Rings Ring Stick
Ring Stick New
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Piston Rings Ring Stick
New
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Piston Rings Ring Stick
Ring Stick
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Oil Sump Engine Cleanliness (sludge & deposits)
Clean Sludge & Deposits
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Oil Sump Engine Cleanliness (sludge & deposits)
Clean
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Oil Sump Engine Cleanliness (sludge & deposits)
Sludge & Deposits
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Rocker Covers Engine Cleanliness
Clean Sludge & Deposits
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Rocker Covers Engine Cleanliness
Clean
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Rocker Covers Engine Cleanliness
Sludge & Deposits
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Con-Rod Bearings Failure
Light Wear Hardware Failure
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Con-Rod Bearings Failure
Light Wear
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Con-Rod Bearings Failure
Hardware Failure
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Cylinder liners
Damage
Minimal Wear Hardware Failure
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Cylinder liners
Damage
Minimal Wear
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Cylinder liners
Damage
Hardware Failure
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Cylinder liners Polish & Gloss
Gloss Bore Polish
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Cylinder liners Polish & Gloss
Gloss
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Cylinder liners Polish & Gloss
Bore Polish
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Turbo Charger Deposits
Good Bad
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Turbo Charger Deposits
Good
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Turbo Charger Deposits
Bad
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Valve train Cam lobes & Followers
Camshaft Lobes
Roller Followers
Good Condition Hardware Failure
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Valve train Cam lobes & Followers
Camshaft Lobes
Good Condition
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Valve train Cam lobes & Followers
Camshaft Lobes
Hardware Failure
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Valve train Cam lobes & Followers
Roller Followers
Good Condition
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Valve train Cam lobes & Followers
Roller Followers
Hardware Failure
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Oil Condition & Analysis
• In order to adequately lubricate, cool and protect engine components within the
recommended oil drain interval, the oil must
• Stay in Grade
• Minimise degradation processes
• Cope with contaminants
• The oil is periodically samples and analysed for
• Preventive Maintenance
• Monitor Engine Condition
• Determine the Life of an Oil
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Oil Condition & Analysis Test Matrix and interpretation
Viscosity
KV Stay in grade. Resistance to shear
HTHS Stay in grade. Resistance to shear
Degradation
TBN Detergency Level. Condemnation limit
TAN Indication of oil condemnation limit
Oxidation General oil depletion
Nitration General oil depletion
Contamination
Diesel/Gasoline Fuel in oil
FAME in oil Bio-fuel in oil
Flash Point Fuel contamination
Soot Combustion contamination
Insolubles Wear particles & oxidation products
Water Coolant. Excessive low temp operation
Glycol Coolant leak
Wear Metals
Iron Ring/Liner wear
Lead Main bearings. Con-rod bearings
Copper Bearing shells. Bushes. Oil coolers
Chromium Ring or bore wear
Molybdenum Ring or bore wear
Aluminium Pistons. Bearings
Additive Metals
Calcium Additive depletion
Magnesium Additive depletion
Zinc Additive depletion
Phosphorus Additive depletion
Contamination Elements
Silicon Airborne dust/dirt particles
Sodium Anti-freeze
Potassium Anti-freeze
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Oil Degradation & Trending TBN retention
0
2
4
6
8
10
12
14
0
2
4
6
8
10
12
14
16
0 50,000 100,000 150,000 200,000 250,000 300,000
cS
t
KO
H/g
Test km
TAN / TBN / KV100
TAN
TBN
KV100
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Oil Degradation & Trending Oxidation & Nitration
0
5
10
15
20
0 50,000 100,000 150,000 200,000 250,000 300,000
A/c
m
Test km
Oxidation / Nitration
Nitration Oxidation
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Oil Degradation & Trending Wear metals
0
20
40
60
80
100
120
140
0 50,000 100,000 150,000 200,000 250,000 300,000
pp
m
Test km
Wear Metals
Iron Lead
Copper Aluminium
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Summary
• Field Trials test a lubricants performance in ‘real world’ service conditions
– Test control is poor vs fired engine testing
– But OEM confidence in field trial output is high
• Key to running successful field trials is good communication and a strong
team mentality between interested parties
– Field Trial Sponsor
– OEM
– Test Sites
– Fleet owners
– Oil analysis laboratories
• Things can and will go wrong
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