Construction equipment engine performance degradation due to environmental and operation factors in Latin America

2019 ◽  
Vol 25 (3) ◽  
pp. 499-524
Author(s):  
Kurt Azevedo ◽  
Daniel B. Olsen
Keyword(s):  
Operating Conditions ◽  
Mitigation Strategies ◽  
Sensor Data ◽  
Engine Oil ◽  
Construction Equipment ◽  
Base Number ◽  
Oil Viscosity ◽  
Mining Operations ◽  
Content Type ◽  
Engine Wear

Purpose The purpose of this paper is to determine whether the altitude at which construction equipment operates affects or contributes to increased engine wear. Design/methodology/approach The study includes the evaluation of two John Deere PowerTech Plus 6,068 Tier 3 diesel engines, the utilization of OSA3 oil analysis laboratory equipment to analyze oil samples, the employment of standard sampling scope and methods, and the analysis of key Engine Control Unit (ECU) data points (machine utilization, Diagnostic Trouble Codes (DTCs) and engine sensor data). Findings At 250 h of engine oil use, the engine operating at 3,657 meters above sea level (MASL) had considerably more wear than the engine operating at 416 MASL. The leading and earliest indicator of engine wear was a high level of iron particles in the engine oil, reaching abnormal levels at 218 h. The following engine oil contaminants were more prevalent in the engine operating at the higher altitude: potassium, glycol, water and soot. Furthermore, the engine operating at higher altitude also presented abnormal and critical levels of oil viscosity, Total Base Number and oxidation. When comparing the oil sample analysis with the engine ECU data, it was determined that engine idling is a contributor for soot accumulation in the engine operating at the higher altitude. The most prevalent DTCs were water in fuel, extreme low coolant levels and extreme high exhaust manifold temperature. The ECU operating data demonstrated that the higher altitude environment caused the engine to miss-fire and rail pressure was irregular. Practical implications Many of the mining operations and construction projects are accomplished at mid to high altitudes. This research provides a comparison of how construction equipment engines are affected by this type of environment (i.e. higher altitudes, cooler temperatures and lower atmospheric pressure). Consequently, service engineers can implement maintenance strategies to minimize internal engine wear for equipment operating at higher altitudes. Originality/value The main contribution of this paper will help construction equipment end-users, maintenance engineers and manufacturers to implement mitigation strategies to improve engine durability for countries with operating conditions similar to those described in this research.

Engine oil degradation analysis of construction equipment in Latin America

2019 ◽  
Vol 25 (2) ◽  
pp. 294-313 ◽  
Author(s):  
Kurt Azevedo ◽  
Daniel B. Olsen
Keyword(s):  
Latin America ◽  
Operating Conditions ◽  
Mitigation Strategies ◽  
Engine Oil ◽  
Oil Degradation ◽  
Laboratory Equipment ◽  
Content Type ◽  
Global Representation ◽  
Engine Maintenance ◽  
Tier 3

Purpose The purpose of this paper is to determine and describe the effect of oil degradation on the engine of a 20-ton class excavator operating in Latin America. Design/methodology/approach The research parameters include: a specific engine class and equipment, the John Deere PowerTech Plus 6068 Tier 3 diesel engine that powers the 20-ton class excavator; identical OSA3 oil analysis laboratory equipment in 11 target countries in Latin America was employed to analyze oil samples; and the same sampling scope and method were followed for each oil sample. Findings The research results indicated that at 500 h of use, 73.4 percent of the oil sample results indicated that soot accumulation was a significant problem. When associating the engine oil contamination with the environment risk drivers: altitude and diesel quality have the greatest impact on iron readings; bio-diesel impacts copper; and precipitation and poor diesel quality are associated with silicon levels. Practical implications Due to diverse machine operating conditions, research offers an accurate global representation. Because there is an exponential count of particles as oil use approaches 250 h, the interval of engine maintenance (oil change) for machinery operating under similar conditions should not exceed 250 h of use. Originality/value The main contribution of this paper will help machinery final users and manufacturers to implement mitigation strategies to improve engine durability in countries with similar operating conditions.

The Influence of Lubricant Supply Conditions and Bearing Configuration on the Performance of (Semi) Floating Ring Bearing Systems for Turbochargers

2017 ◽  
Author(s):  
Luis San Andrés ◽  
Feng Yu ◽  
Kostandin Gjika
Keyword(s):  
Heat Flow ◽  
Thermal Energy ◽  
Operating Conditions ◽  
Temperature Fields ◽  
Engine Oil ◽  
Large Temperature ◽  
Oil Viscosity ◽  
Supply Pressure ◽  
The Impact ◽  
Bearing System

Engine oil lubricated (semi) floating ring bearing (S)FRB systems in passenger vehicle turbochargers (TC) operate at temperatures well above ambient and must withstand large temperature gradients that can lead to severe thermo-mechanical induced stresses. Physical modeling of the thermal energy flow paths and an effective thermal management strategy are paramount to determine safe operating conditions ensuring the TC component mechanical integrity and the robustness of its bearing system. On occasion, the selection of one particular bearing parameter to improve a certain performance characteristic could be detrimental to other performance characteristics of a TC system. The paper details a thermohydrodynamic model to predict the hydrodynamic pressure and temperature fields and the distribution of thermal energy flows in the bearing system. The impact of the lubricant supply conditions (pressure and temperature), bearing film clearances, oil supply grooves on the ring ID surface are quantified. Lubricating a (S)FRB with either a low oil temperature or a high supply pressure increases (shear induced) heat flow. A lube high supply pressure or a large clearance allow for more flow through the inner film working towards drawing more heat flow from the hot journal, yet raises the shear drag power as the oil viscosity remains high. Nonetheless, the peak temperature of the inner film is not influenced much by the changes on the way the oil is supplied into the film as the thermal energy displaced from the hot shaft into the film is overwhelming. Adding axial grooves on the inner side of the (S)FRB improves its dynamic stability, albeit increasing the drawn oil flow as well as the drag power and heat flow from the shaft. The predictive model allows to identify a compromise between different parameters of groove designs thus enabling a bearing system with a low power consumption.

Field-Testing of Biodiesel (B100) and Diesel-Fueled Vehicles: Part 2—Lubricating Oil Condition Monitoring

2020 ◽  
Vol 143 (4) ◽  
Author(s):  
Avinash Kumar Agarwal ◽  
Deepak Agarwal
Keyword(s):  
Thermal Stability ◽  
Trace Metal ◽  
Condition Monitoring ◽  
Direct Injection ◽  
Field Testing ◽  
Ash Content ◽  
Operating Conditions ◽  
Lubricating Oil ◽  
Base Number ◽  
Oil Viscosity

Abstract This study investigated the use of biodiesel (B100) and baseline diesel in two identical unmodified vehicles to realistically assess different aspects of biodiesel’s compatibility with modern common rail direct injection (CRDI) diesel engines and its effects on lubricating oil degradation and wear. Two identical vehicles were operated for 30,000 km each under identical operating conditions on highway during a field-trial while using biodiesel (B100) and baseline mineral diesel. Exhaustive experimental results from this series of tests were divided into four segments, and this paper covers the second segment showing the effect of long-term usage of biodiesel on the lubricating oil properties and traces of wear metal addition compared to baseline mineral diesel. Lubricating oil samples were drawn periodically from these vehicles for condition monitoring such as lubricating oil viscosity, density, soot content, total base number (TBN), ash content, trace metal concentrations, and thermal stability. The viscosity of lubricating oil samples drawn from biodiesel fueled vehicles were found to be ∼10–15% lower compared to that from diesel-fueled vehicles, whereas density and ash content were relatively lower by ∼5–10%. Carbon residues of lubricating oil samples drawn from B100 fueled vehicles were lower by ∼15–20% compared to that of diesel-fueled vehicles. There was a very strong reduction (∼70%) in the soot content of lubricating oil from biodiesel fueled vehicles. Trace metal analysis to compare wear debris addition was also done for all lubricating oil samples. Thermo-gravimetric analyses of lubricating oil samples from biodiesel fueled vehicles showed lower mass loss with increasing temperature hence relatively higher thermal stability and lower deterioration. Results also suggested that operational and durability issues associated with vegetable oils as alternate fuel were completely eliminated by using them after converting them into biodiesel meeting prevailing biodiesel specifications.

Comparing oil condition in diesel and gasoline engines

2020 ◽  
Vol 72 (8) ◽  
pp. 1033-1039
Author(s):  
Adam Agocs ◽  
Serhiy Budnyk ◽  
Marcella Frauscher ◽  
Bettina Ronai ◽  
Charlotte Besser ◽  
...  
Keyword(s):  
Design Methodology ◽  
Engine Oil ◽  
Base Number ◽  
Oil Degradation ◽  
Special Issue ◽  
Maintenance Strategies ◽  
Content Type ◽  
Gasoline Engines ◽  
Total Base ◽  
New Generation

Purpose This paper aims to compare the conditions of in-service oils from diesel and gasoline engines, with focus on nitration. Design/methodology/approach Oil conditions of seven engine oil samples from five diesel-fueled vehicles and nine oil samples from eight gasoline-fueled vehicles with total mileage ranging from 13,600 to 30,000 km were determined via Fourier-transform infrared spectroscopy as well as neutralization number (NN) and total base number titration. Findings Chemical deterioration was characterized by significant differences in oxidation, nitration, NN increase and residual aminic antioxidant contents. Social implications Submitted in connection with the Special Issue, “Young Tribologists – Insights into the work of the new generation”. Originality/value Uncovering differences in the oil degradation of oils from gasoline and diesel engines enables improved condition-based maintenance strategies and the prediction of oil condition dependent tribological performance.

Experimental study of starvation in grease-lubricated finite line contacts

2017 ◽  
Vol 69 (6) ◽  
pp. 963-969 ◽  
Author(s):  
Zhijian Wang ◽  
Xuejin Shen ◽  
Xiaoyang Chen ◽  
Qiang Han ◽  
Lei Shi
Keyword(s):  
Film Thickness ◽  
High Viscosity ◽  
Operating Conditions ◽  
Test Rig ◽  
Oil Viscosity ◽  
Content Type ◽  
Base Oil ◽  
Optical Test ◽  
Line Contacts ◽  
Finite Line

Purpose The purpose of this paper is to study starvation in grease-lubricated finite line contacts and to understand film-forming mechanisms of grease-lubricated finite line contacts. Design/methodology/approach A multiple-contact optical elastohydrodynamic (EHL) test rig is constructed to investigate the influences of lubricant properties on film thickness and lubrication conditions at different working conditions. The film thickness is calculated according to the relative light intensity principle. The degree of starvation is evaluated by the air–oil meniscus distance and the corresponding film thickness. Findings The experimental results show that for greases with high-viscosity base oil, the high-frequency fluctuation of film thickness is observed in low-speed operating conditions. Reducing the viscosity of the base oil and improving running speed can weaken the fluctuation of film thickness. The degree of starvation increases with increasing base oil viscosity, rolling speed and the crown drop. In addition, reducing the replenishment time by reducing the gap between the rollers also can increase the degree of starvation. Originality/value Starvation is often to occur in finite line contacts, such as roller bearings and gears; there are still limited finite line contact EHL test rigs, much less multiple-contact optical test rigs. Therefore, the present work is undertaken to construct the multiple-contact test rig and to evaluate the mechanism of starvation in finite line contacts.

On the Influence of Lubricant Supply Conditions and Bearing Configuration to the Performance of (Semi) Floating Ring Bearing Systems for Turbochargers

2017 ◽  
Vol 140 (3) ◽  
Author(s):  
Luis San Andrés ◽  
Feng Yu ◽  
Kostandin Gjika
Keyword(s):  
Thermal Energy ◽  
Operating Conditions ◽  
Temperature Fields ◽  
Engine Oil ◽  
Large Temperature ◽  
Oil Viscosity ◽  
Supply Pressure ◽  
Oil Flow ◽  
The Impact ◽  
Bearing System

Engine oil-lubricated (semi) floating ring bearing ((S)FRB) systems in passenger vehicle turbochargers (TC) operate at temperatures well above ambient and must withstand large temperature gradients that can lead to severe thermomechanical induced stresses. Physical modeling of the thermal energy flow paths and an effective thermal management strategy are paramount to determine safe operating conditions ensuring the TC component mechanical integrity and the robustness of its bearing system. The paper details a model to predict the pressure and temperature fields and the distribution of thermal energy flows in a bearing system. The impact of lubricant supply conditions, bearing film clearances, and oil supply grooves is quantified. Either a low oil temperature or a high supply pressure increases the generated shear power. Either a high supply pressure or a large clearance allows more flow through the inner film and draws more heat from the hot journal, thought it increases the shear drag power as the oil viscosity remains high. Nonetheless, the peak temperature of the inner film is not influenced by the changes on the way the oil is supplied into the film as the thermal energy displaced from the hot shaft into the film is overwhelming. Adding axial grooves on the inner side of the (S)FRB improves its dynamic stability, albeit increasing the drawn oil flow as well as the drag power and heat from the shaft. The results identify a compromise between different parameters of groove designs thus enabling a bearing system with a low power consumption.

Embedded Digital Twins in future energy management systems: paving the way for automated grid control

2020 ◽  
Vol 68 (9) ◽  
pp. 750-764
Author(s):  
Christoph Brosinsky ◽  
Rainer Krebs ◽  
Dirk Westermann
Keyword(s):  
Power System ◽  
Real Time ◽  
Energy Management ◽  
Situation Awareness ◽  
Operating Conditions ◽  
Mitigation Strategies ◽  
Sensor Data ◽  
Reference Network ◽  
Measurement Information ◽  
Simulation Engine

AbstractEmerging real-time applications in information technology, and operational technology enable new innovative concepts to design and operate cyber-physical systems. A promising approach, which has been discovered recently as key technology by several industries is the Digital Twin (DT) concept. A DT connects the virtual representation of a physical object, system or process by available information and sensor data streams, which allows to gather new information about the system it mirrors by applying analytic functions. Thereby the DT technology can help to fill sensor data gaps, e. g., to support anomaly detection, and to predict future operating conditions and system states. This paper discusses a dynamic power system DT as a cornerstone instance of a new generation of EMS, and a prospective new EMS architecture, to support the increasingly complex operation of electric power systems. Unlike in traditional offline power system models, the parameters are updated dynamically using measurement information from the supervisory control and data acquisition (SCADA) and a wide area monitoring system (WAMS) to tune the model. This allows to derive a highly accurate virtual representation of the mirrored physical objects. A simulation engine, the Digital Dynamic Mirror (DDM) is introduced, in order to be able to reproduce the state of a reference network in real-time. The validation of the approach is carried out by a case study. In a closed loop within EMS applications, the DDM can help to assess contingency mitigation strategies, thus it can support the decision-making process under variable system conditions. The next generation of control centre Energy Management System (EMS) can benefit from this development by augmentation of the dynamic observability, and the rise of operator situation awareness.

On the Effect of Thermal Energy Transport to the Performance of (Semi)Floating Ring Bearing Systems for Automotive Turbochargers

2012 ◽  
Author(s):  
Luis San Andrés ◽  
Vince Barbarie ◽  
Avijit Bhattacharya ◽  
Kostandin Gjika
Keyword(s):  
Heat Flow ◽  
Thermal Energy ◽  
Energy Transport ◽  
Operating Conditions ◽  
Engine Oil ◽  
Distinct Advantage ◽  
Oil Viscosity ◽  
Wide Range ◽  
Thermal Energy Transport ◽  
Bearing System

Bearing systems in engine-oil lubricated turbochargers (TCs) must operate reliably over a wide range of shaft speeds and withstanding severe axial and radial thermal gradients. An engineered thermal management of the energy flows into and out of the bearing system is paramount to ensure the components mechanical integrity and the robustness of the bearing system. The bearings, radial and thrust type, act both as a load bearing and low friction support with the lubricant carrying away a large fraction of the thermal energy generated by rotational drag and the heat flow disposed from a hot shaft. The paper introduces a thermohydrodynamic analysis for prediction of the pressure and temperature fields in a (semi) floating ring bearing system. The analysis solves simultaneously the Reynolds equation with variable oil viscosity and the thermal energy transport equation in the inner and outer films of the bearing system. Flow conditions in both films are coupled to the temperature distribution and heat flow thru the (semi)floating ring. Other constraints include calculating the fluid films’ forces reacting to the externally applied load and to determine the operating journal and ring eccentricities. Predictions of performance for a unique realistic (S)FRB configuration at typical TC operating conditions reveal distinct knowledge: (a) the heat flow from the shaft into the inner film is overwhelming, in particular at the inlet lubricant plane where the temperature difference with the cold oil is largest; (b) the inner film temperature increases quickly as soon as the (cold) lubricant enters the film and due to the large amount of energy generated by shear drag and the heat transfer from the shaft; (c) a floating ring develops a significant radial temperature gradient; (d) at all shaft speeds, low and high, the thermal energy carried away by the lubricant streams is no less that 70% of the total energy input; the rest is conducted through the TC casing. To warrant this thermal energy distribution, enough lubricant flow must be supplied to the bearing system. The efficient computational model offers a distinct advantage over existing lumped parameters thermal models and with no penalty in execution time.

On the Effect of Thermal Energy Transport to the Performance of (Semi) Floating Ring Bearing Systems for Automotive Turbochargers

2012 ◽  
Vol 134 (10) ◽  
Author(s):  
Luis San Andrés ◽  
Vince Barbarie ◽  
Avijit Bhattacharya ◽  
Kostandin Gjika
Keyword(s):  
Heat Flow ◽  
Thermal Energy ◽  
Energy Transport ◽  
Operating Conditions ◽  
Engine Oil ◽  
Distinct Advantage ◽  
Oil Viscosity ◽  
Wide Range ◽  
Thermal Energy Transport ◽  
Bearing System

Bearing systems in engine-oil lubricated turbochargers (TCs) must operate reliably over a wide range of shaft speeds and withstand severe axial and radial thermal gradients. An engineered thermal management of the energy flows into and out of the bearing system is paramount in order to ensure the component’s mechanical integrity and the robustness of the bearing system. The bearings, radial and thrust type, act both as a load bearing and low friction support with the lubricant carrying away a large fraction of the thermal energy generated by rotational drag and the heat flow disposed from a hot shaft. The paper introduces a thermohydrodynamic analysis for the prediction of the pressure and temperature fields in a (semi) floating ring bearing (S)FRB system. The analysis simultaneously solves the Reynolds equation with variable oil viscosity and the thermal energy transport equation in the inner and outer films of the bearing system. Flow conditions in both films are coupled to the temperature distribution and heat flow through the (semi) floating ring. Other constraints include calculating the fluid films’ forces reacting to the externally applied load and to determine the operating journal and ring eccentricities. The predictions of performance for a unique realistic (S)FRB configuration at typical TC operating conditions reveal a distinct knowledge: (a) the heat flow from the shaft into the inner film is overwhelming, in particular, at the inlet lubricant plane where the temperature difference with the cold oil is largest; (b) the inner film temperature quickly increases as soon as the (cold) lubricant enters the film and is due to the large amount of energy generated by shear drag and the heat transfer from the shaft; (c) a floating ring develops a significant radial temperature gradient; (d) at all shaft speeds, low and high, the thermal energy carried away by the lubricant streams is no less than 70% of the total energy input; the rest is conducted through the TC casing. To warrant this thermal energy distribution, enough lubricant flow must be supplied to the bearing system. The efficient computational model offers a distinct advantage over existing lumped parameters thermal models and there is no penalty in the execution time.

Effect of Stationary Natural Gas Engine Oils on Fuel Economy

2012 ◽  
Author(s):  
Nikhil Dayanand ◽  
John D. Palazzotto ◽  
Alan T. Beckman
Keyword(s):  
Natural Gas ◽  
Fuel Consumption ◽  
Fuel Economy ◽  
Operating Conditions ◽  
Specific Fuel Consumption ◽  
Engine Oil ◽  
Brake Specific Fuel Consumption ◽  
Oil Viscosity ◽  
Gas Engine ◽  
Natural Gas Engine

In order to investigate the possible environmental and economic benefits of lubricants optimized for stationary natural gas engine efficiency, a decision was made to develop a test stand to quantify the effects of lubricant viscosities and formulations on the brake specific fuel consumption. Many fuel economy tests already exist for evaluating gasoline and heavy duty diesel motor oils which have proven the benefit of fuel economy from different lubricant formulations. These engines would not be suitable tools for evaluating the fuel economy performance of lubricating oils formulated specifically for stationary natural gas engines, since there are significant differences in operating conditions, fuel type, and oil formulations. This paper describes the adaptation of a Waukesha VSG F11 GSID as a tool to evaluate fuel consumption performance. The performance of brake specific fuel consumption when using different formulations was measured at selected high loads and rated speed. The results of the testing program discuss the viscosity and additive effects of stationary natural gas engine oil formulations on brake specific fuel consumption. The results will detail the change in brake specific fuel consumption between natural gas engine oil formulations blended to varying viscosities and compared to a typical natural gas engine oil formulation with a viscosity of 13.8 cSt @ 100°C. The second portion of the test program explores the effect of different additive packages that were blended to the same finished oil viscosity. It was acknowledged that there were statistical differences in brake specific fuel consumption characteristics between lubricants different in viscosity and additive formulations.

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