OILS & LUBRICANTS consume up to four litres of fuel for each hour it is left idling , meaning there are significant environmental and financial benefits to be gained if idling time can be reduced . When engines idle extensively , oil consumption and the side effects can damage engines . Volatility is an important characteristic when choosing an oil for engines in this operating environment . Engine oils with poor volatility can cause engine oil consumption and fouling within the exhaust gas recirculation ( EGR ) systems . When an oil has poor volatility characteristics , the oil turns to a vapour which can be seen as oil consumption and buildup of deposits and sludge within the engine .”
Idling can have hidden and significant impacts on the equipment engine . The detrimental impact on engine wear increases as engine loading is reduced , which can in turn alter the combustion process . This can result in fuel dilution and the accumulation of moisture and soot , which can lead to an increased risk of acid formation , in addition to possibly reducing oil viscosity . Regular and prolonged idling can therefore accelerate engine wear and shorten oil drain intervals , even though the vehicle ’ s hour meter or maintenance schedule might state differently .
“ Using a quality lubricant can improve an engine ’ s pumping and cranking efficiencies while minimising metal-to-metal contact between moving components . This protects the engine ’ s vital components , which enhances its performance and may help improve fuel economy , so the choice of lubricant and suitable viscosity grade should not be overlooked . For those within heavy-duty off-highway industries such as mining , the benefits of API CK-4 oils are particularly applicable . Oils that meet this specification protect against oxidisation and aeration , as well as offering increased shear stability . Mining equipment engines can be more heavily loaded at the bearings , which require an oil film to ensure protection , and can benefit from improved aeration control .”
Susinski argues that is also important to consider that mining equipment operates in some of the coldest conditions , so it is essential to select an oil that benefits from cold weather performance characteristics . A low temperature viscosity oil enables easier cold starts and provides added protection against frequent stop and starts , which supports the ability of the engine to be turned off to reduce idling . In these colder conditions , a high viscosity oil can resist pumping and cranking and delay lubrication to critical engine components , which can impact the protection of the engine and increase wear . Industry standard tests such as ‘ Cold Crank Viscosity ’ ( ASTM D5293 ) and ‘ Borderline Pumping Viscosity ’ ( ASTM D4684 ) should be reviewed when choosing a lubricant that will protect critical components in the coldest of operating conditions .
“ To monitor the impact of engine idling , operators should incorporate used oil analysis into their maintenance routine . This can highlight maintenance issues caused by regular and prolonged idling before they become too serious or expensive to repair . Oil analysis and robust maintenance programs are key components in tackling and monitoring the impact of idling in harsh conditions . A superior lubricant can also offer essential protection for engine components , protecting them from the hidden impacts of engine idling such as fuel dilution and soot loading .”
He concludes : “ The impact of engine idling can be significant for off-highway engines , especially those in the mining industry where equipment is under pressure to operate reliably in extreme conditions . However , there are proactive measures that can be taken to reduce the negative effects of idling on fuel economy and engine wear . Regular oil analysis , a proactive maintenance program and , above all , a quality lubricant can reduce the impact of idling and help avoid unplanned downtime .”
Advanced filtration systems for oils and lubricants
In the mining industry , “ time is money ,” is meant quite literally . To make sure you stay in the black , you need to get the most out of every minute . And that means getting the most out of every piece of equipment .
Nate Zambon , Director of Filter Minder at Donaldson told IM : “ Making sure that everything is running as it should , when it should , is vital to keeping your entire operation running smoothly . In the harsh environments of mining , there ’ s no way to completely avoid unexpected downtime on a job site . But what if you could better control what is in your control ? If you knew more about your equipment ’ s systems - notably the filters and engine oil - you could know what to expect and plan for it .”
Zambon says it ’ s widely accepted that it ’ s best to change your filters at a predetermined time of year or at a set interval . “ But if the filter has sufficient life remaining to hit the next interval , you can maximise consumption and get more productivity out of your fleet . Using advanced
telematics and sensors integrated into the fluid and filtration systems , we ’ re now able to generate real-time data to create more efficient service scheduling , including optimal filter replacement timing . This wireless sensing capability sends filter and fluid performance data to the cloud , while predictive analytics help users make more efficient filtration maintenance decisions .”
This technology eliminates a lot of the guesswork when it comes to filtration and oil performance . By continually monitoring the oil and the filter , Zambon argues you can answer a lot of questions and improve your equipment ’ s efficiency . “ Should the fluid be changed ? Does the condition of the fluid indicate a larger problem in the engine ? Using existing fleet monitoring software , these sensors send messages in real time that can prevent a minor issue from turning into a major repair .”
The more downtime on a mining site , the more money and time ( also money ) you haemorrhage . “ If you knew that you could deliver greater uptime on your equipment by being proactive and ‘ listening ’ to the equipment , wouldn ’ t you do so ? You can avoid a lot of surprises that can bring the work to a screeching halt . It ’ s now possible to listen to your entire fleet at once . Telematics have advanced so much that we can connect multiple monitoring solutions into one intuitive system . It ’ s the next stage of wireless filtration and fluid monitoring technology .”
Donaldson uses technology that allows integrated data from all onboard systems - air , fuel , oil and hydraulics - into the GeoTab fleet management platform no matter the fleet or engine . This means it ’ s now easy to put what could otherwise be an overwhelming amount of information into action . It also means more informed maintenance decisions , which means more uptime and more productivity . And more productivity is the ultimate goal .
IM
Donaldson is using advanced telematics and sensors integrated into fluid and filtration systems
JULY 2021 | International Mining 47