Heavy Duty Engine Oils-Field Trials

FIELD TRIALS
KEY ELEMENT OF R&D AND OEM

CO-OPERATION
Frank Machatschek
Product Application Specialist, Europe
Copyright of Shell Global Solutions
Why Field Trials? Our Motivation (1)

Key element of Product Development and Performance Demonstration
Real world testing ultimate proof of performance
Test limits in tough operating conditions to ensure right performance
Ensure product will deliver what we claim
Focus on:
Wear protection AND cleanliness
Extended oil drain capability
EATS compatibility
Fuel economy
Long term performance
Helping customers to use the right

product and solving problems
hence reducing operating costs
Why Field Trials? Our Motivation (2)

Key element of co-operation with leading truck OEMs
Joint testing of prototype engines and engine oils, joint engine inspections at EOT
Understanding of future hardware needs
Ability to unleash the full potential of advanced lubricants
Co-op with Mercedes-Benz Trucks:
Germany
China
India
South Africa
UAE
USA
OEMs appreciate technical support
Mercedes- Benz Supplier Award 2014 Goes To Shell

March 2015: Shell received Mercedes-Benz Supplier Award 2014 at
Daimler HQ Germany in the Partnership category for outstanding
performance
Wendelin Wolbert (Vice President Daimler International Procurement

Systems)
with Shell Global Key Account Management
(1) Extended Oil Drain Interval And Long-term Performance

Rimula R6 LM/LME 5W-30 in 4 MB Citaro O530 G, SOT: 07/2008
Demanding conditions, incline up to 12%, 300 m stop and go
Fuel consumption up to 65-70 L/100 km, but only GVW 29 to
Engine milage: up to 473.000 km
ODI recommended: 60.000 km, ODI field trial: 120.000 - 147.000 km
3 oil drains in 7 years !!!
(1) Extended Oil Drain Interval And Long-term Performance

Bus #7142
Bus #7143
Bus #7144
Bus #7145
Extremely low wear rates

300
Fe
Fe Limit, high: 250 ppm
[ppm]
Fe Limit, elevated: 200 ppm
200
100
Engine Milage [km]
0
Copyright
0 of Shell Global Solutions100,000
200,000
300,000
400,000
500,000
(2) Engine Cleanliness And Extended ODI

Rimula R6 LM 10W-40 in 3 MB Actros
5.000 m altitude
Rugged off-road, incline up to 15%
50-60 tonnes
2.000 ppm S in fuel
Fuel consumption > 100 L/100 km

Turbocharger deposits and damages
Cost of turbocharger ~ 1.600 US$
Latest model T/C even more costly
Mineral oil 15W-40
Rimula R6 LM 10W-40

300
Fe
[ppm]
Operating Window:
Recommended ODI: 250 hrs
Limit Fe Wear high: 250 ppm
200
100
Oil Milage [hrs]
0
0
100
200
300
400
500
600
(3) Soot Handling Capability

Each new wave of emission legislation (up to Euro 3) has resulted in
increased stress on the oil due to higher soot levels
Retarded injection and EGR
Soot load has increased by over 100% from API CG-4 to API CI-4
Possible effects: increased wear and oil thickening

Rimula R6 LM 10W-40 in 11 MAN Euro 1 D0826 engines, 6,8 L, 198 kW
a) High soot loading and b) heavy oil deposits in air compressor
ODI from 30.000 km to 60.000 km with Rimula R6 LM 10W-40
10
Soot in oil [%]

8
Extremely high soot level
Normal soot level
0
0
10,000
20,000
30,000
40,000
Oil Milage [km]
50,000
60,000

Air compressor discharge pipes: same application but different oil
Conventional Oil 15W-40
Rimula R6 LM 10W-40
after 50.000 km
after 50.000 km
Rimula R6 LM 10W-40
after 100.000 km
(4) Scania Long Drain Field Trial

Rimula R6 M 10W-40 in 3 Scania R440
Up to 45% EGR (Euro 5/6) plus high S-Level in fuel high TBN retention is required
2 x ODI 120k km according to Scania long drain field trial protocol
Joint engine inspection after 250.000 km


Extremely good condition of the engine
clean grooves to prevent ring sticking

contact pattern


(5) Biofuel
Biofuel leads to viscosity reduction and corrosive wear
Performance impact
Impact on Engine Oil
General impact
Burns differently
More gets into oil
Sump Over-fill
Lower viscosity
Wax forms at low temperature
Additives degrade
Acids form
Less Soot in oil
Wear!
Pumping problems
Shorter oil life (ODI)
Metal corrosion
(5) Biofuel: Viscosity Reduction
14
Fresh Oil Viscosity: 11,6 mm2/s
12
kV
10
@ 100C
[mm2/s]
recommended oil drain
-36%
VISCOSITY !
0
0
10,000
20,000
30,000
40,000
50,000
Oil Milage [km]
60,000
70,000
80,000
90,000
(5) Biofuel: Engine Inspection

Rimula R6 LM/LME
Doubled oil drain interval
Test duration: 500.000 km
(5) Biofuel: Extremely Extended ODI With Rimula R6 LM
300
Fe
[ppm]
200
Operating Window:
Recommended ODI:
50,000 km
Limit Fe Wear high:
250 ppm
100
Oil Milage [km]
0
Copyright
Global Solutions
0 of Shell
20,000
40,000
60,000
80,000
100,000
120,000
140,000
160,000
180,000
200,000
(5) Biofuel: Extremely Good Engine Condition

500.000 km / 3 oil drains in 5 years!!
Rimula R6 LM proviced excellent wear protection and cleanliness
(6) Future Low Viscosity Engine Oil Validation

USA: Prototype engine oils with HTHS 2,9 instead of 3,5 (10W-20/30)
16 Mio mls controlled tests, 10 engine inspections @ 500.000 mls
60.000 mls ODI in Volvo, DDC, Paccar, Navistar

2011/2012 MY DDC DD15
200
High shear rate: nrotor: 3.200 min-1
High temperature: 150C
175
Limit as of now: 3,5
150
Rotella T TP 15W-40
Rotella T5 10W-30
Rotella T5 10W-30 Low HTHS
Iron, ppm
125
100
75
Cylinder
50
25
Rotor
Lubricant
20,000
40,000
60,000
Oil Miles
80,000
100,000
120,000

USA: Prototype engine oils with HTHS 2,9 instead of 3,5 (10W-20/30)
16 Mio mls controlled tests, 10 engine inspections @ 500.000 mls
60.000 mls ODI in Volvo, DDC, Paccar, Navistar

HTHS 2,9 Field Trial Scania
2 x 120k km (75k ml) ODI
Engine inspection
Wear pattern similar to HTHS 3,5 viscosity
(7) Pionieering Extended Oil Drain Interval In India

Rimula R6 M 10W-40 in 7 BharatBenz
Daimler India introduced first series of trucks in Sept 2012
Presence in all major truck segments from 9 to 49 tones GVW
Rimula R6 M 10W-40 exclusive FFO for Mercedes-Benz India with extended ODI
ODI:
ODI:18k
18kkm
km36k
36kkm
km
ODI:
ODI:50k
50kkm
km100k
100kkm
km

108.643 km
18
Oil-Milage
102.626 km
17
kV100
16
14
SAE 40
[mm2/s] 15
fresh oil viscosity
13
SAE 30
12
11
10
9
8
7
6
100,000
150,000
200,000
Engine Milage [km]
250,000
300,000
350,000

108.643 km
300
Fe
Oil-Milage
102.626 km
250
[ppm]
200
Fe Limit, elevated: 200 pm
150
100
50
0
100,000
150,000
200,000
Engine Milage [km]
250,000
300,000
350,000
(8) Ultimate Proof Of Performance

Mercedes-Benz`s accelerated prototype test circuit in South Africa
Very latest engine technology Euro 6+
Rugged topography, high load and high speed
Euro 6 engine
Severity Factor: 3
Extended Oil Drain
South Africa
Europe
ODI:
75.000 km 210.000 km
Test period:
500.000 1.500.000 km

Shell Rimula R6 LM/LME in Mercedes-Benz`s
LATEST:
Euro 6
LARGEST:
15,6 L
STRONGEST:
625 hp and 3.000 Nm
Avg fuel consumption: 72 L/100 km
Avg monthly milage: 27.000 km

0,5 Mio km in 1,5 years
0,5 Mio km x SF 3 = 1,5 Mio km = MB`s new engine lifetime target

75.000 km ODI x SF 3 = 210.000 km = MB`s new ODI target

Oil temperature mainly between 110-120C
Frequency
[%]
Oil Temperature [C]

240
220
94.249 Oil km
76.086 Oil km
75.386 Oil km
74.987 Oil km
75.986 Oil km
76.826 Oil km
200
Al,
180
Fe,
160
Cu,
140
Pb,
120
Cr
100
80
Si
60
40
20
50
0,
00
0
Engine Milage [km]
45
0,
00
0
40
0,
00
0
35
0,
00
0
250.000
30
0,
00
0
25
0,
00
0
20
0,
00
0
15
0,
00
0
500
10
0,
00
0
50
,0
00
[ppm]
500.000

Joint engine inspection at Mercedes-Benz`s Global R&D Center

Shell Rimula R6 LM/LME demonstrated superior protection and
cleanliness in Daimler`s latest engine generation

Shell Rimula R6 LM/LME demonstrated superior protection and
cleanliness in Daimler`s latest engine generation
Quiz Quiz Quiz Quiz Quiz Quiz Quiz Quiz Quiz Quiz
Question:
What is the severity factor in South Africa?
(9) EATS Compatibility: Ash Loading/DPF Clogging

Ash leads to increased back pressure and maintenance cost

4 city buses, Euro 3 OM 906 engine, 5 years
Backpressure over DPF and ash mass in DPF
Doubling of cleaning interval with Rimula R6 LM

300
Backpressure
[mbar]
250
Rimula R6 LM 10W-40
conventional oil 15W-40
200
150
100
50
40
0,0
00
35
0,0
00
30
0,0
00
200.000
25
0,0
00
20
0,0
00
15
0,0
00
10
0,0
00
50
,00
0
0
400.000
DPF Milage
[km]

Ash mass in DPF
DPF milage: 225.000 km
Oil consumption: 0,3 L / 1.000 km
Rimula R6 LM
Ash Mass:
0,53 kg
Conventional
1,21kg
(10) Fuel Economy in Volvo Euro 5
4x identical Volvo FH12

D13C Euro 5 engine, 460 hp
5.0%
Error bars: 95% Confidence Intervals
4.5%
Top-Tier
4.0%
Experimental
% FE Benefit vs. Baseline
3.57%
3.5%
3.18%
3.0%
2.88%
2.51%
2.5%
2.0%
1.91%
2.00%
1.59%
1.5%
1.37%
1.0%
0.5%
0.0%
SORT Cold
SORT HOT
SORT AVG
Highway
(11) Fuel Economy Field Trial In TATA BS III Engines
Shell Rimula T5 E 10W-30
Vehicles: 4 x TATA vehicles BS III
Test Oils: 15W-40 vs 10W-30
Duration: 6.000 - 10.000 km each vehicle
Swapping test oils several times
Each period ~ 1.200 km

6
22
21
20
[L/100 Km]
15W-40
[Km/L]
5.9
10W-30
Fuel
Consumption [L/100 km]
5.8
15W-40 vs 10W-30
5.7
15W-40
10W-30
5.6
19
5.5
18
5.4
17
5.3
16
5.2
period 1 period 2 period 3 period 4 period 5 period 6 period 7
Sept
Oct
Nov
Dec
Jan
Feb
Mar
Swapping test oils several times
Each period ~ 1.200 km
3%+ FE
compared to 15W-40
6
22
21
20
[L/100 Km]
15W-40
[Km/L]
5.9
10W-30
Fuel
Consumption [L/100 km]
5.8
15W-40 vs 10W-30
5.7
15W-40
10W-30
5.6
19
5.5
18
5.4
17
5.3
16
5.2
period 1 period 2 period 3 period 4 period 5 period 6 period 7
Sept
Oct
Nov
Dec
Jan
Feb
Mar
Fuel Is The 2nd Largest Cost Block

FE calculation xls sheet
Fuel Economy Calculation: Current Fuel Cost
Copyright of
Average Fuel Consumption:

Annual Vehicle Milage:
Annual Fuel Demand:
Fuel Price:
Annual Fuel Costs:
L/100k m
km
L/vehicle
/L
$/vehicle
34
130.000
44.200
1,00
$44.200
Fuel Economy:
Less Fuel Cost:
%
$/vehicle
0,50
$221
Oil Sump Volume:
15W-40 Oil Price:

Number Of Oil Drains Per Year:
Annual Oil Demand Per Year:
Annual Oil Cost Per Year:
$/L
5W-30 Oil Price:

$/L
L/ vehicle
$/vehicle
3,00
1,0
40
120
Higher Oil Cost:
$/vehcile
-24
$/vehicle
$197
100
$19.700
Annual Saving Per Vehicle:

vehicles:
ShellNumber
Global Solutions
Total Annual Saving:
L//vehicle
$/vehicle
$/fleet
40
1,20
2,0
80
96
Fuel Economy Calculation: Fuel Saving
Copyright of

Annual Fuel Demand:
Fuel Price:
Annual Fuel Costs:
L/100k m
km
L/vehicle
/L
$/vehicle
34
130.000
44.200
1,00
$44.200
Fuel Economy:
Less Fuel Cost:
%
$/vehicle
1,50
$663
Oil Sump Volume:
15W-40 Oil Price:

$/L
5W-30 Oil Price:

$/L
L/ vehicle
$/vehicle
3,00
1,0
40
120
Higher Oil Cost:
$/vehcile
-24
$/vehicle
$639
100
$63.900

vehicles:
ShellNumber
Global Solutions
L//vehicle
$/vehicle
$/fleet
40
1,20
2,0
80
96
FE benefit with
Rimula R6 LME 5W-30
Fuel Economy Calculation: Additional Oil Cost
Copyright of

Annual Fuel Demand:
Fuel Price:
Annual Fuel Costs:
L/100k m
km
L/vehicle
/L
$/vehicle
34
130.000
44.200
1,00
$44.200
Fuel Economy:
Less Fuel Cost:
%
$/vehicle
1,50
$663
Oil Sump Volume:
15W-40 Oil Price:

$/L
5W-30 Oil Price:

$/L
L/ vehicle
$/vehicle
3,00
1,0
40
120
Higher Oil Cost:
$/vehcile
-24
$/vehicle
$639
100
$63.900

vehicles:
ShellNumber
Global Solutions
L//vehicle
$/vehicle
$/fleet
FE benefit with
Rimula R6 LME 5W-30
40
1,20
2,0
80
96
Extended ODI with

Rimula R6 LME 5W-30
Fuel Economy Calculation: Bottom Line
Copyright of

Annual Fuel Demand:
Fuel Price:
Annual Fuel Costs:
L/100k m
km
L/vehicle
/L
$/vehicle
34
130.000
44.200
1,00
$44.200
Fuel Economy:
Less Fuel Cost:
%
$/vehicle
1,50
$663
Oil Sump Volume:
15W-40 Oil Price:

$/L
5W-30 Oil Price:

$/L
L/ vehicle
$/vehicle
3,00
1,0
40
120
Higher Oil Cost:
$/vehcile
-24
$/vehicle
$639
100
$63.900

vehicles:
ShellNumber
Global Solutions
L//vehicle
$/vehicle
$/fleet
FE benefit with
Rimula R6 LME 5W-30
40
1,20
2,0
80
96
Extended ODI with

Rimula R6 LME 5W-30
Without labour cost,

downtime etc
Field Trials
Key Element of R&D activities and customer support
Customers want PROOF and no promises wrt performance and benefits
Real World operating conditions give best proof of performance
>500 vehicles every day in the year in tests worldwide, and we will continue

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FIELD TRIALS

KEY ELEMENT OF R&D AND OEM

Copyright of Shell Global Solutions

Why Field Trials? Our Motivation (1)

Real world testing ultimate proof of performance

Test limits in tough operating conditions to ensure right performance

Ensure product will deliver what we claim

Wear protection AND cleanliness

Extended oil drain capability

Long term performance

Helping customers to use the right

Copyright of Shell Global Solutions

Why Field Trials? Our Motivation (2)

Understanding of future hardware needs

Ability to unleash the full potential of advanced lubricants

Co-op with Mercedes-Benz Trucks:

OEMs appreciate technical support

Copyright of Shell Global Solutions

Mercedes- Benz Supplier Award 2014 Goes To Shell

Wendelin Wolbert (Vice President Daimler International Procurement

(1) Extended Oil Drain Interval And Long-term Performance

Demanding conditions, incline up to 12%, 300 m stop and go

Fuel consumption up to 65-70 L/100 km, but only GVW 29 to

Engine milage: up to 473.000 km

ODI recommended: 60.000 km, ODI field trial: 120.000 - 147.000 km

3 oil drains in 7 years !!!

Copyright of Shell Global Solutions

(1) Extended Oil Drain Interval And Long-term Performance

Extremely low wear rates

Fe Limit, high: 250 ppm

Engine Milage [km]

(2) Engine Cleanliness And Extended ODI

Rugged off-road, incline up to 15%

2.000 ppm S in fuel

Fuel consumption > 100 L/100 km

Copyright of Shell Global Solutions

(2) Engine Cleanliness And Extended ODI

Cost of turbocharger ~ 1.600 US$

Latest model T/C even more costly

Mineral oil 15W-40

Copyright of Shell Global Solutions

(2) Engine Cleanliness And Extended ODI

Oil Milage [hrs]

Copyright of Shell Global Solutions

(3) Soot Handling Capability

Retarded injection and EGR

Possible effects: increased wear and oil thickening

Copyright of Shell Global Solutions

(3) Soot Handling Capability

a) High soot loading and b) heavy oil deposits in air compressor

ODI from 30.000 km to 60.000 km with Rimula R6 LM 10W-40

Soot in oil [%]

Extremely high soot level

Normal soot level

Oil Milage [km]

Copyright of Shell Global Solutions

(3) Soot Handling Capability

Copyright of Shell Global Solutions

(4) Scania Long Drain Field Trial