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SHELL FLEET TECHNOLOGY TOUR

August 29, 2011

VALUE DELIVERY THROUGH SERVICES

OIL CONDITIONING MONITORING PROGRAM

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SETTING UP AN EFFECTIVE OIL ANALYSIS PROGRAM

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Why Conduct Oil Analysis?—Identify and measure oil contamination—Monitor product performance—Monitor component wear

Potential Benefits—Increase equipment availability by decreasing equipment

downtime—Increase overall component life span—Monitor product performance and optimize oil service

intervals—Decrease fuel and oil consumption

What Equipment Should You Sample On?—Equipment integral to a proactive maintenance program

OIL ANALYSIS PROGRAM SAMPLING PROCEDURES

Three Easy Steps:

1. Take a Proper Sample2. Supply Sample

Information3. Send Samples to the

Lab

TAKING A PROPER SAMPLE IS CRITICAL

Sampling Procedures— Equipment should be run at

temperature prior to sampling— Take sample within 30 minutes

of shutdown— Whenever possible take

sample while lubricant is circulating (sample valve only)

— Take samples the same way each time….

Consistency Is the Key

SUPPLY SAMPLE INFORMATION

Provide Sample Information—Fill out forms as completely as possible—Fill out label on the sample container—When possible, provide an equipment list

to the lab before sampling starts (preloaded in lab’s computer system)

Oil samples must be accompanied with:—Sample origin (Name and Address)—Sample date—Unit or engine identification—Unit hours or miles—Oil hours or miles—Quantity of oil added this sampling period—Quantity of oil low (based on dipstick)—Oil brand name and viscosity grade

Take the sample today, send it today

PROPER SAMPLING INTERVALS AND THE RIGHT TESTS ARE KEY

Engine Oil Testing Components—Spectrographic Analysis of

Metals—Fuel Dilution (% volume)—Fuel Soot (% weight)—Water (% volume)—Viscosity (cSt @100° C)—Glycol from coolant

(positive / negative)—Total Base Number (TBN)

—Total Acid Number (TAN)

Sampling Considerations:—Operating priority of equipment—Current PM, lube and filter schedules—OEM recommendations or

requirements—Environmental influences (dust,

water, etc.)—Current or historical problems of

specific or like equipment—Specific goals of program objectives—Adjust as appropriate

SPECTROGRAPHIC ANALYSIS HELPS US TRACK 3 KEY THINGS

Component wear metals:—Iron, Chromium, Nickel,

Molybdenum, Aluminum, Lead, Copper, Tin, Silver

Contaminants: —Silicon, Sodium, Boron,

Potassium

Additives:—Phosphorous, Zinc,

Calcium, Barium, Boron, Molybdenum, Magnesium

TESTING CAN ALSO REVEAL PRESENCE OF FUEL, SOOT, AND WATER

Typical Causes of Fuel Dilution—Worn, leaking, damaged injectors—Improperly adjusted fuel system

settings—Excessive idling / lugging

Fuel Dilution Effects—Decrease in viscosity:

— 5% = approx. 1 SAE Grade Loss

— Reduced lubrication— Increased wear rates

—Decreased fuel efficiency

Causes for High Soot—Incomplete combustion—Improperly adjusted fuel system

settings—Restricted air intake or exhaust—Worn or mismatched injectors—Excessive idling and/or lugging—Deficient fuel properties

Soot Actions/Effects—Naturally attracted into gel

formations—Hardened by heat to form deposits—Loads and depletes dispersant

additives—Plugs oil filters—Increases viscosity

Water Sources/Causes —Bulk oil contamination—Low operating temp.—Defective seals / gaskets—Cracked head / block, liner, injector

tube, etc.—Defective water pump—Oil cooler, heat exchanger tubing

Actions/Effects—Surface corrosion / rust —Changes in viscosity—Loss of additive performance—Increased sludge—Decreased filter performance—Increase in oxidation and foam

tendency

DATA INTERPRETATION: READING REPORTS

Types Of Applied Limits:— Set Values – Minimum

or Maximum— Set by component

OEM’s and analytical labs

— Values vary by type of components, equipment make/model, application

—Trend Analysis – for change

— Values developed based on allowable deviations from analytically established baseline

— Combinations of the above

TAKING ACTION ON THE DATA

When A Change Occurs:— Look for corresponding

cause or reason— Contaminant, viscosity

change, etc.

— Look for a confirming related change

— Increased viscosity with increased solids, etc.

— Look for identifying components

— Water + Na + B or K = Cooling System Leak

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EXAMPLE: OIL ANALYSIS HELPS FLEET CUSTOMER SAVE OVER $46,0000 IN ENGINE REBUILDS *

Large Shell Fleet customer in US worked with Shell to establish oil analysis program as part of maintenance cost containment/reduction measures

Specific focus on in-warranty equipment sampling at PM intervals to identify potential issues (particularly signs of high wear) prior to warranty expiration

Testing results indicated abnormal results indicating excessive bearing overlay wear in 3 units

Resulting action required: 2 engine overhauls in-frame

1 engine replaced

Since issues were spotted while under warranty, there was no cost to the fleet for repairs

One of the units repaired was at 486K miles with warranty expiring at 500K miles!*Savings indicated specifically calculated from actual customer value delivery example

KEYS TO A SUCCESSFUL USED OIL ANALYSIS PROGRAM

Clearly defined goals and program requirements

Representative samples

Complete sample information

Frequent customer-laboratory contact