ENHANCEMENT OF ENGINE OIL

& FILTER LIFE AND

OVERALL
PERFORMANCE OF ENGINE

Introduction
Diesel Engines operational efficiency largely
depends on the performance of following:
Fuel system,
Lubricating Oil system &
Air System.
Thus ensuring use of high quality Diesel,
quality air intake, good lubricating oil &
monitoring its condition consistently, can
fetch better efficiency, longer life of Diesel
engine & its component & huge
saving on
oil & filters.

Prospective

Engine built in system has its own limitation &

thus need frequent change of filters, oil to
maintain the condition of oil, fuel & air.
On further study of available literatures, review
of technologies & discussion with OEM & oil
manufacturer, it was felt that there is a scope
for extending oil drain interval / filter life & yet
maintain the desired condition through
scientific approach.

It was also understood that by exploring all

possibilities in line with available guidelines
from OEM & Lubricant Manufacturer & adopting
new technology, a substantial benefit can be
achieved.
Some prominent achievable benefits
Direct benefits
Higher Engine Oil life
Higher filters life
Higher fuel economy
Extended overhaul period
Higher availability of Equipment

All the above will lead to Huge cost saving

Other benefits:
Lesser Engine related trouble
Lesser Component failure
Lesser Emission (Environmental Benefit)
Higher overall engine efficiency
Lesser use of Natural Resources &
Lesser waste disposal hazard
With a view to achieve all the benefit listed
above an initiative was undertaken with all
necessary, precautionary measures & prior
approval, to establish extended service life of
Oil & Filters.

Approach
Following steps were undertaken to establish oil
drain interval & filter life.
Guidelines were obtained from OEM (Cummins)
for extending oil drain interval.
Guidelines were obtained from Oil manufacturer
for rejection criteria of Oil.
The matter were also discussed with industry
oil experts for further clarification and
revalidation.
Based on the Guidelines provided by Cummins
& Shell India ltd, Engine oil samples were
collected carefully & tested at oil manufacturers
laboratory in stages.

 Based on the test reports & interpretation of

results, oil life was extended in stages up to
800 hrs as all parameters were within limit.
Further possibility was explored through
available technology & few modern gadgets
like on-line oil, Fuel & Air purifier were added
in two RTG for a trail run.
All parameters including oil sample test
reports
were closely monitored till 1600 hrs in stages
& found to be well within limit.
Oil was replaced after 1600 hrs of run & it was
decided to check the internal condition of
Engine through endoscopy, as engine had
covered more than 5500 hrs of total running.

On line Oil Purifier

On line Fuel Purifier

On Line Air Purifier

 Shell India ltd. who provides such special

services (to its customers) were invited &
carried out the video endoscopy for the
engines.
Internal condition of engines was found to be
very good during the Endoscopy.
On further monitoring of parameter, later it was
decided to defer the filters replacement
schedule to double of its recommended life.
Based on the success of the trail, online Air, Fuel
& Oil purification units were installed in all RTG.

Video check Endoscopy instrument

Major Benefits Achieved :

Cost savings of $ 68,900 in Year 2010 on

Engine Oil & Filters only.
Cost saving of $ 22,358 in Year 2010 due to
better Fuel Economy.
Also benefits like reduction in overall
maintenance cost, lesser engine related
trouble, higher equipment availability, less
manpower requirement, lesser use of natural
resources, & many other benefits achieved.
Cost of Implementation - $. 83,850 only.
Overall ROI Approx One year.

Oil Consumption and Engine Running Comparison

10000
9000

8000

0
0

7000

6000

#REF!
Engine Running
oil Consumption

5000
0

4000

0
0

3000

0
0

2000
0
0

1000
1

0
0

0
0

Fuel Consumption Rate

20.00
19.00
18.00
17.00
16.00
15.00
14.00
13.00
12.00
11.00
10.00

18.24

18.13

13.57
11.79

17.63

13.37

Fuel
Consump/Hr
Moves rate/Hr

Thank
You