Post on 03-Jan-2016
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A Suncor Energy business
ENERGY EFFICIENCIESENERGY EFFICIENCIESMaximize The Opportunity – Select the Right LubricantMaximize The Opportunity – Select the Right Lubricant
ALBERTA FOREST PRODUCTS ASSOCIATIONALBERTA FOREST PRODUCTS ASSOCIATION
SEPTEMBER 2012
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OBJECTIVE
• This presentation is to review the opportunities in reaching energy efficiencies and prolonging equipment and oil life in the forestry industry.– Traditional thinking
• Indoor: Mono-grade oils• Outdoor: Multi-grade oils
• We will discuss advantages of moving to multi-grade lubricants indoors.
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FORESTRY - INDUSTRY TRENDS• Overall reduction in costs (who isn’t)• Energy consumption reflects a substantial
operational cost for the Forestry industry• Hydraulic systems are becoming smaller but more
efficient resulting in higher temperatures and pressures
• A typical hydraulic pump converts approx 20% of its horsepower into heat, therefore most fluids run at elevated temperatures
• Gear design changes to improve efficiency require gear lubricants to work at higher temperatures.
OPPORTUNITIES FOR CHANGE
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OPPORTUNITIES FOR CHANGE
• The trends and more severe requirements on today’s hydraulic and gear systems can and are met with existing high quality mono-grade (straight-grade, single-grade) oils.
• However, further improvements in performance, as well as an added bonus in energy efficiencies is possible through the use of non-traditional products multi-grade oils in indoor applications.
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FUNCTIONS OF A LUBRICANT
• Reduce FrictionReduce Friction
• Minimize Wear (Keep Moving Surfaces Apart)Minimize Wear (Keep Moving Surfaces Apart)
• Cool Parts (Carry Away Heat)
• Prevent Corrosion
• Disperse Combustion or Oxidation by-products
• Act as a Sealant
• Transmit Power
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• Lubrication is key when sliding (area) contact is present.• Lubricants are used to reduce friction and wear by preventing metal to metal contact.
No Lubricant: High Friction
Full Film (Hydrodynamic) Lubrication: Low Friction
Thin Film (Boundary) Lubrication: Moderate Friction
SteelSteel
SteelSteel
SteelSteel
SteelSteel
SteelSteel
SteelSteel
Air
Oil Film
WHY LUBRICATE?
7*NRC Report published in 1986
FRICTION - 1986 NRC-ACOT REPORT
• $5 Billion* per year is lost in Canada due to friction and wear
• 25 - 30% is recoverable with existing technology
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FRICTION - 1986 NRC-ACOT REPORT
Friction Losses ($million/year)
Wear Losses ($million/year)
Total Losses ($million/year)
Agriculture 321 940 1,261
Electric Utilities 54 189 243
Forestry 111 158 269
Mining 211 728 940
Pulp and paper 105 382 487
Rail Transportation 284 467 750
Trucks and buses 126 860 986
Wood Industries 14 189 203
TOTALS 1,2261,226 3,9133,913 5,1395,139
1986 to 2012 what is the $$ amount today? Significant opportunity to reduce friction losses
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• Viscosity is a measurement of resistance to flow at one temperature.
• Viscosity Index (VI) is a measurement of the rate of change of viscosity over a range of temperatures. In simple terms: it measures how fast the oil thickens up as it gets colder or how fast it thins out as it gets hotter.
• Generally the higher the VI the more all-season the product
LUBRICANT PROPERTIES
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• Viscosity Index is an inherent property of the base oil used to blend a lubricant.– Some oils have naturally higher VI than others (i.e. Group II
or synthetics)
• VI can be improved significantly by blending soluble additives called VI Improvers (VII) into the oil.
• These additives are long polymer molecules which uncoil at high temperatures to increase viscosity, while at low temperatures they form tight “balls” which no longer contribute much to viscosity.
VISCOSITY INDEX
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VISCOSITY INDEX IMPROVER (VII)
Temperature oC (LOG)
Vis
cosi
ty c
St
(LO
G-L
OG
)
Base OilMono-grade Product(i.e. Hydraulic AW)
Base Oil + VIIMulti-grade (all-season) Product
(i.e. Hydraulic MV)Viscosity Index Improver (VII) additive expands with higher temperatures resulting in a
higher viscosity at high temperatures
Potential reduction based on shear stability
(i.e. quality) of VII.
Viscosity increase at low temperatures is relatively small resulting in cold temperature
viscosity near original base oil.
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VISCOSITY INDEX IMPROVER (VII)
Temperature oC (LOG)
Vis
co
sit
y c
St
(LO
G-L
OG
)
Mono-grade ProductMono-grade Product(i.e. Hydraulic AW 32)(i.e. Hydraulic AW 32)
Multi-grade ProductMulti-grade Product(i.e. Hydraulic MV 32)(i.e. Hydraulic MV 32)
-20 10040
OEM Recommended
Operating Range
Gain in effective operating temperature rangeGain in effective operating temperature range
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OPPORTUNITIES FOR CHANGE
• Although all indoor components may see benefits of multi-grade oils the two biggest opportunities in the forestry industry are:– Hydraulics
– Gear systems
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VISCOSITY IMPACT - HYDRAULICSV
isco
sity
(cS
t)
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INDUSTRIAL GEAR APPLICATIONS
• Basic Principles• Rolling at the pitch point• Sliding occurs above and below the pitchpoint
Original animation by Doug Wrighte, UWAModified by Fluid Life
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HYDRAULIC PUMP EFFICIENCY
Volumetric Efficiency: All pumps have internal leakage paths.Mechanical Efficiency: Energy is consumed to rotate pump and overcome fluid frictional losses.The amount of mechanical and volumetric loss in a pump is primarilya function of the fluid’s viscosity and lubricity properties.
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HYDRAULIC PUMP EFFICIENCY
Ref: Evonik Industries
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SHEAR STABILITY IS IMPORTANT
Ref: Evonik Industries
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SHEAR STABILITY IS IMPORTANT
Ref: Evonik Industries
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OEMS LIMITS ON SHEAR STABILITY
OEM Max Shear LossEaton/Vickers 10% 20 hr KRLPoclain 10% 40 min SonicJCB OEM 10% 20 hr KRLVolvo Construction 12% 20 hr KRLParker/Denison 15% 20 hr KRLKomatsu HK-1 12% 20 hr KRLCaterpillar TO-4 15% 20 hr KRLBosch/Rexroth 15% 20 hr KRLSauer/Danfoss 15% 40 min SonicDin 51524 Part 3/ ISO 6473 HM Type3 15% 40 min SonicKubota UDT 15% 250 cycle Kurt OrhbanJohn Deere 40 min Sonic Vis @ 100C min of 7.2 cst
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INDUSTRY - TEST RESULTS
Ref: RohMax
COMPONENTTEST OILS
% ENERGY SAVINGSMono-grade Multi-grade
Gear Pump
Eaton L2 Series 2550
ISO 46
VI 100
ISO 46
VI 150>4
Vane Pump
Denison T6C
ISO 46
VI 100
ISO 46
VI 150>5
Piston Pump
Komatsu HPV 35+35
ISO 46
VI 100
ISO 46
VI 150>15
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INDUSTRY – TEST RESULTS
Source: Evonik Industries
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INTERNAL HYDRAULIC OIL TESTS
IMPROVEMENT AW vs. MV
0
1
2
3
4
5
6
50 60 70 80
Temperature C
% Im
pro
vem
ent
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GEAR OIL TESTS RESULTS
GL-5 80W-90
Synthetic Blend 75W-90
Synthetic 75W-90
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FIELD TEST RESULTS
• Test results indicated a fuel savings of 3.8% ($8740)
SAE 10W Mono-grade Multi-grade ISO 32
Hours of Work / Drain Interval Hours 4000 4000
System Volume (gallons) 67.4 67.4
$/gallon $11.70 $6.09
$/litre $3.10 $1.61
Cost of Oil ($) $789 $411
Energy Efficiency Gain 0% 2.8%
Fuel Consumed (gallons) 24,459 21,114
Fuel Costs ($/gallon) $2.50 $2.50
Total Fuel ($) $61,148 $52,785
TOTAL COSTS $61,936 $53,196
Field trial done by vendor on a medium size excavator with dual piston pump feeding 3 piston motors (tracks and swivel) plus boom, stick and bucket cylinders (5000 psi / 345 bar max.) Each product ran for 4 days (~6 hours / day)
Results above are extrapolated to 4000 hrs using a Denison T6CM pump (B10 cartridge, 2000 rpm, 200 bar, 70oC) to benchmark field trial products and internal multi-grade. Since the efficiency of the pump is based on viscometric properties of the fluid at certain temperatures and pressure conditions, data can be accurately extrapolated from the field trial and bench tests to other products.
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SUMMARY
• Significant opportunities are available to improve energy efficiencies by changing to multi-grade oils in applications otherwise suitable for mono-grade products.
• Multi-grade hydraulic and gear oils that are shear stable will maintain viscosity and allow operations to run under wider temperatures
• Improved shear stability results in improved energy efficiencies
• Although much of the test results shown in this presentation are related to mobile equipment, the opportunities of energy efficiencies are relevant to all equipment based on the lubricant technology.
• Selecting the right multi-grade oil saves money.
Thank-you for your time & interest