Our accomplice, a taconite mine in northern Minnesota, has an extended historical past with utilizing Mobil Delvac 1ESPTM artificial engine oils of their fleet of 30 Komatsu 830E haul vans, powered by Cummins QSK 60 engines. Over time, the mine has elevated engine oil drain intervals as much as 2000 hours and has realized elevated gear availability and manufacturing ranges. This success is attributed to utilizing one of the best Mobil lubricants mixed with a disciplined, data-driven strategy taken by their reliability crew in direction of upkeep.
The mine has already realized over $900K in annual financial savings from this program.
The mine strives to be a frontrunner within the iron ore business via protected workplaces, operational effectivity, and environmental stewardship. As a part of assembly this ambition, the Mobil ServSM Engineering crew and the reliability crew on the mine wished to know what else could possibly be executed to enhance effectivity on the mine.
The problem recognized: Can we safely prolong our engine rebuild cycle past 28,000 hours?
One truck was chosen for prolonged testing – which represented the standard situation of the fleet’s engines. This unit was at 28,000 hours and oil
evaluation continued to point out very low put on metals with no notable put on development. Along with oil evaluation, an in-truck load check was accomplished to gauge engine output horsepower. This check confirmed no energy loss within the engine, which helped
verify the dearth of wear and tear proven in oil evaluation.
The crew was assured that the engine might nonetheless carry out properly, and determined to go away it in service till it reached 36,000 hours. They usually had been proper! In depth testing on the engine at 36,000 hours proved it might even have gone additional.
The outcomes
“This new technique will ship important financial savings to our accomplice, as the whole profit calculated is over $1.7 million {dollars}.” Jonathan Leland, Mobil Serv Lubrication Engineer, Minneapolis, MN
Engine dynamometer testing: The primary check accomplished after the engine was taken
out was dyno-testing at a Cummins facility. The outcomes had been spectacular – crankcase blow-by was nonetheless inside spec of a brand new engine. Horsepower scores additionally confirmed the excellent situation of the engine. Once more, the engine was nonetheless inside specs of a brand new engine displaying a horsepower output of 94%.
Engine score: The following step was to examine the engine after it was taken aside. This was executed in collaboration with the ExxonMobil Analysis and Engineering (EMRE) crew of consultants. EMRE employs ASTM licensed elements raters together with Victor Veiga, who has over 30 years of expertise working with engine testing and evaluations.
Primary bearings: Nearly all of the bearings have very minimal put on and are in excellent situation. 10-15% worn space is excellent for this engine and responsibility cycle. This
signifies constant safety from the oil all through the lifetime of the engine. Primarily based on the total outcomes, the common put on and uncovered copper could be very spectacular for an engine of this age and working below extreme responsibility cycle.
Pistons: That is an space the place poor engine oil will result in extra carbon deposits and extra put on. As a complete, these pistons are very, very clear — that is proof of how Mobil Delvac 1ESPTM has helped keep cleanliness of the engine.
Piston liners: The interface between the pistons and liners is an space the place poor oil efficiency will present itself in a telling put on sample. If the oil just isn’t defending properly and begins to interrupt down at longer oil drain intervals, this space of excessive warmth and combustion supplies will present the oil’s lack of efficiency. The unique cross-hatching continues to be seen and the journey vs. non-travel areas look the identical.
Valves: Consumption valve score offers a way of the air high quality coming into the piston, whereas exhaust valve score tells of the standard of combustion fuel leaving the piston. With out correct air filters and poor combustion, these valves can develop into very soiled
and start carrying the valve seats (sealing floor). Once more, we see very spectacular outcomes! Nearly all of the valves from this engine present lower than 20% protection and all consumption and exhaust valve surfaces had been clear, and free of wear and tear on the valve
face and stem.
Conclusion
The general situation of the engine was extraordinarily good based mostly on the variety of hours and extreme responsibility cycle. Primarily based on the crew’s findings, the mine goes to increase haul truck engine rebuild technique to 40,000 hours. This allows elevated haul truck utilization and decreased haul truck operational prices and advances the mines ambitions via confirmed engineering knowledge.