Performance you can rely on.

Field testing

InfineumInsight.com/Learn

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 Performance you can rely on.

Topics

• Why run field trials

• Heavy Duty & Passenger Car Field Trial Overview
• Field Trial Overview
• Field Trial Execution
– pre-trial & during trial
– post-trial
• Component rating (pass/fail, good/bad) examples
• Oil condition & analysis
– degradation & trending
• Summary

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 Performance you can rely on.

Why run Field Trials

Formal OEM Approvals Demonstration of performance and Marketing

• Some OEMs only approve oils by field • Further validation of performance following
testing static engine and laboratory tests
• Others require field test data to support read • Proof of performance
across • No harm testing
• Generation of marketing data
Development or Evaluation • Fuel Economy demonstrations
• New Additive Packages or components
• Unconventional Base Stocks
• Unconventional fuels
• Alternative viscosity grades
• Extended Oil Drain Intervals
• New Engine Hardware
• Comparative evaluation
vs. fired engine or bench tests

Field Trials run by Infineum are initiated by internal programmes, OEM’s or customers requirements.

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Why run Field Trials

Increasing cost and time to acquire data

Bench Tests – Rig Tests – Engine Tests – Field Trials – End Application

Less representative of in-service performance

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Why run Field Trials.

• OEMs require field tests to ensure oil quality remains appropriate for
• Increased demand on oil
• Hardware changes and additions

• Field tests give them high confidence because the tests are carried out in
realistic end-user conditions.

• Increasing stress on oil:

• extended oil drain intervals
• smaller sump sizes
• higher engine outputs
• stricter emission legislation
• Fuel economy oils

• Some HD OEM’s operate a finished lubricant based approval system.

• Others only require field trials after significant lubricant formulation changes.

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Typical field trial (Overview)

Heavy Duty & Passenger Car Motor Oil

HD PCMO
Vehicles per candidate 3 3
Field trial length 300,000 km 100,000 km
Oil drain interval 100,000 km 15,000 km
Used oil sampling frequency 25,000 km 5,000 km
Drive cycle Long Haul (44-60 T) 20% urban, 80% motorway
Vehicle source Fleet operator vehicles Purchased vehicles
Fleet owner drivers
Mileage accumulation Fleet owner drivers
Contract drivers

Time to complete 18-24 months 4-12 months

EOT engine strip and rebuild OEM approved Workshops Contract workshops

Participation at EOT engine Infineum, OEMs & Independent Infineum & Independent
inspection accredited raters accredited raters

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Typical field trial (Overview)

• OEM’s specify or endorse proposals for:

• Vehicle and engine type
• Overall test distance and oil drain interval
• Drive cycles, routes and engine severity

• During the field trial, oil samples are periodically taken and analysed:
• To ensure oil quality is maintained during oil drain intervals
• To ensure there are no problems with the engine

• At the end of the field trial, engines are stripped:

• Pistons are rated for carbon deposits
• Bearings, liners and valve train are rated for wear
• Oil sump, covers and components are rated for general cleanliness
• Other components are also rated

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Field Trial Execution

Process and Control

Pre-Trial and during Trial

Clearly defined and understood procedures are key:

• Flush cycle prior to Start of Test (SOT)

• Oil and filter changes at SOT
• Oil sampling according to the test plan
• Sampling equipment, technique, & labelling, are all important considerations
• Oil changes according to the test plan
• Steps to avoid lubrication mistakes
• Accurate record keeping
• Oil consumption
• Fuel consumption
• Unusual service events
• Deviations from plan
• Continuous, honest and open communication

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Field Trial Execution

Process and Control
Post-Trial
Clearly defined engine strip down procedure prior to inspection:

• Number and lay out components according to their cylinder position

• Pistons, with piston rings still in place
• Oil Sump and Cylinder Head Cover(s) inverted and allowed to drain
• Valve train gear dismantled
• Valves removed from Cylinder Heads
• Crankshaft & Camshaft made accessible
• Main and Con-rod Bearing shells removed
• Cylinder Liners removed
• Turbo Charger, & Oil Mist Separator removed & dismantled
• Oil pump opened
• Other parts as required by OEMs are also inspected

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Engine dismantled for inspection

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End of Trial Engine inspection

Components from each vehicle is inspected, rated and photographed.
• Pistons (deposits) • Engine Cleanliness (deposits, sludge)
• 1st & 2nd Grooves. • Sump
• Land(s) • Engine Block
• Piston Rings (ring stick, wear, deposits, pitting) • Covers
• Top Ring • Valve Train (wear)
• 2nd Ring • Cam Followers
• Oil Control Ring • Pushrods
• Liners/Bores (wear, gloss, polish, lacquer, corrosion) • Rocker bushes
• Ring Reversal • Rocker pads
• Swept Area • Valve bridges
• Bearings, Bushes & Journals (wear, pitting) • Valves & Head (wear, deposits)
• Crankshaft • Inlet valve & port deposits
• Camshaft (lobes) • Valve faces & Seats
• Gudgeon pins • Valve stems & valve guides
• Main Bearings • Other
• Con-rod (big end) bearings • Turbo (deposits)
• Small end bushes • Thrust bearings (wear)
• Filtration systems (cleanliness, deposits, sludge)

Ratings, photos and used oil analysis data from all vehicles are compiled into a final field trial
report.

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Pistons
Merit ratings

50.9 Merit Rating. 13.7 Merit Rating.

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Pistons
Merit ratings
50.9 Merit Rating

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Pistons
Merit ratings
13.7 Merit Rating

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Piston Rings
Ring Stick

New Ring Stick

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Piston Rings
Ring Stick

New

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Piston Rings
Ring Stick

Ring Stick

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Oil Sump
Engine Cleanliness (sludge & deposits)

Clean Sludge & Deposits

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Oil Sump
Engine Cleanliness (sludge & deposits)
Clean

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Oil Sump
Engine Cleanliness (sludge & deposits)
Sludge & Deposits

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Rocker Covers
Engine Cleanliness

Clean Sludge & Deposits

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Rocker Covers
Engine Cleanliness

Clean

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Rocker Covers
Engine Cleanliness

Sludge & Deposits

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Con-Rod Bearings
Failure

Light Wear Hardware Failure

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Con-Rod Bearings
Failure

Light Wear

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Con-Rod Bearings
Failure

Hardware Failure

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Cylinder liners
Damage
Minimal Wear Hardware Failure

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Cylinder liners
Damage
Minimal Wear

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Cylinder liners
Damage
Hardware Failure

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Cylinder liners
Polish & Gloss

Gloss Bore Polish

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Cylinder liners
Polish & Gloss
Gloss

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Cylinder liners
Polish & Gloss

Bore Polish

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Turbo Charger
Deposits

Good Bad

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Turbo Charger
Deposits
Good

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Turbo Charger
Deposits
Bad

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Valve train
Cam lobes & Followers

Good Condition Hardware Failure

Camshaft
Lobes

Roller
Followers

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 Performance you can rely on.

Valve train
Cam lobes & Followers

Good Condition

Camshaft
Lobes

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 Performance you can rely on.

Valve train
Cam lobes & Followers

Hardware Failure

Camshaft
Lobes

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Valve train
Cam lobes & Followers

Good Condition

Roller
Followers

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Valve train
Cam lobes & Followers

Hardware Failure

Roller
Followers

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Oil Condition & Analysis

• In order to adequately lubricate, cool and protect engine components within the
recommended oil drain interval, the oil must
• Stay in Grade
• Minimise degradation processes
• Cope with contaminants

• The oil is periodically samples and analysed for

• Preventive Maintenance
• Monitor Engine Condition
• Determine the Life of an Oil

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Oil Condition & Analysis

Test Matrix and interpretation

Viscosity Wear Metals

KV Stay in grade. Resistance to shear Iron Ring/Liner wear

HTHS Stay in grade. Resistance to shear Lead Main bearings. Con-rod bearings
Degradation Copper Bearing shells. Bushes. Oil coolers
TBN Detergency Level. Condemnation limit Chromium Ring or bore wear
TAN Indication of oil condemnation limit Molybdenum Ring or bore wear
Oxidation General oil depletion Aluminium Pistons. Bearings
Nitration General oil depletion Additive Metals
Contamination Calcium Additive depletion
Diesel/Gasoline Fuel in oil Magnesium Additive depletion
FAME in oil Bio-fuel in oil Zinc Additive depletion
Flash Point Fuel contamination Phosphorus Additive depletion
Soot Combustion contamination Contamination Elements
Insolubles Wear particles & oxidation products Silicon Airborne dust/dirt particles
Water Coolant. Excessive low temp operation Sodium Anti-freeze
Glycol Coolant leak Potassium Anti-freeze

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Oil Degradation & Trending

TBN retention

TAN / TBN / KV100

16 14

14
12

cSt
12
10

10
KOH/g

6
6

4
4

2
2

0 0
0 50,000 100,000 150,000 200,000 250,000 300,000

TAN Test km

TBN
KV100

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Oil Degradation & Trending

Oxidation & Nitration

Oxidation / Nitration
20

15
A/cm

10

0
0 50,000 100,000 150,000 200,000 250,000 300,000

Nitration Test km
Oxidation

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Oil Degradation & Trending

Wear metals

Wear Metals
140

120

100

80
ppm

60

40

20

0
0 50,000 100,000 150,000 200,000 250,000 300,000

Iron Copper Test km

Lead Aluminium

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Summary
• Field Trials test a lubricants performance in ‘real world’ service conditions
– Test control is poor vs fired engine testing
– But OEM confidence in field trial output is high

• Key to running successful field trials is good communication and a strong

team mentality between interested parties
– Field Trial Sponsor
– OEM
– Test Sites
– Fleet owners
– Oil analysis laboratories

• Things can and will go wrong

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