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      The gain and pain in extending oil drain intervals in Hydraulic Systems

      Oil drain intervals (ODI) have generally been pre-determined by the Original Equipment Manufacturer (OEM) and designed as such to provide protection to the compartments based on a wide variety of conditions. Over recent years there has been a growing trend within the mining industry to extend ODI beyond the OEM recommended service intervals. Considering hydraulic systems, extending ODI are perceived to be one area where value can be easily delivered to the mining or power generation industries. This can be achieved if carried out correctly but it is important to understand the key risks involved with ODI extension as well as understanding what other tests are required to get a clear idea of the overall health of the oil especially in large volume hydraulic systems.

       

      The current practice particularly within the mining industry tends to be to hook up the hydraulic system to kidney loop filtration units during the scheduled maintenance plan for said equipment. Whilst good practice, the function of kidney looping is to essentially remove particulate particles and even moisture from the system. The removal of such contaminates helps to reduce wear of oil wetted components. In addition, laboratory test packages associated with routine oil analysis of hydraulic oil samples tend to cover only the following tests:

      • Spectrometric analysis (wear metals)
      • Viscosity
      • Moisture
      • Cleanliness

      Some oil analysis laboratories will also carry out Fourier Transform Infra-red spectroscopy (FTIR) on samples but most would be reluctant to admit being able to accurately predict oxidation and overheating of the hydraulic oil based on the FTIR results. 

      As such, on receipt of an oil analysis report, many Reliability Engineers (RE) or Maintenance Professionals make a call that the lubricant health is satisfactory based on low wear metals, stable viscosity and of course, the ISO cleanliness code. The decision to extend the oil past the oils ‘use by date’ is not based on a holistic picture as the health of the lubricant in this instance, cannot be based on those 3 indicators.

      By this, maintenance teams and reliability engineers review the oil analysis reports placing a large emphasis on cleanliness results. If the ISO cleanliness results are at an acceptable code, then the call to extend the oil is made. In some instances, the hydraulic oil type selected by the company may invariably be a standard mineral hydraulic oil where some OEM’s and lubricant companies would only suggest a 2000 hour oil drain interval. In some instances, companies have been known to extend the ODI of large hydraulic excavator systems well past the capability of the hydraulic lubricant with the decision made based on viscosity and cleanliness of the lubricant. This approach, whilst initially leading to reduced oil consumption savings, does not take into cognisance the actual health of the oil which in time will lead to equipment issues resulting in increased maintenance activities and operational cost. A very important test measure not included as a standard measure in routine analysis of hydraulic oil samples is anti-oxidant content. 

       

      When oils are exposed to the process of oxidation, oxidative products are formed. Increases in oxidation could be as a result of excessive operating temperatures or even from a process known as “microdieseling” which occurs when entrained air bubbles implode when being passed through high pressure zones within the system. This results in very high localised temperatures of the oil resulting in oxidative by-products being formed.

      Lubricants contain anti-oxidants to combat the process of oxidation but additives are sacrificial in nature and ultimately get “used up”. When the anti-oxidants within the lubricant gets too low, then oxidation of the oil accelerates. This, together with an ineffectual method to remove these oxidative by-products, ultimately leads to varnish formation. These varnish deposits will tend to drop out of solution and at the areas that are coolest in the hydraulic or turbine system thus leading to equipment unreliability, for example, sticking of servo valves. The formation of varnish does not happen overnight but rather is an accumulation of continued over-extension of the hydraulic oil, sometimes taking more than 5 years before the presence of varnish within the hydraulic system becomes apparent. 

      Test results from routine used oil analysis do not detect the level or anti-oxidants in the oil and cannot determine potential formation of varnish. Similarly, routine used oil analysis cannot be used as the main justification for extending oil drain periods. In the case of Hydraulic systems using a standard hydraulic oil, it is important for maintenance professionals to liaise with the laboratory to include other tests. As a minimum, Acid Number (AN) or Total Acid Number (TAN) must be included in the routine suite of tests. In addition, at 2000 hours operating time on oil and every subsequent 1000 operating hours on the oil thereafter, tests to confirm anti-oxidant levels left in the lubricant should be carried out in order to determine the overall health of the lubricant. By closely monitoring physical and chemical characteristics, a call can be made that the oil is at or nearing the end of its useful life. This can be determined by closely monitoring any increasing trend in TAN which is also likely to be accompanied by very small incremental increases in viscosity. This trend, together with decreasing anti-oxidant levels in the oil means that the hydraulic oil must be replaced.

      In addition and as a supplement to the above, laboratories can perform Membrane Patch Colorimetry (MPC). Here, a set volume of oil is passed through a filter membrane, also referred to as a patch. The patch is then compared against known reference patches and a number assigned to the patch. The higher the assigned number, the higher the amount of varnish precursors present in the oil.

      LubAnac (ANAlysis Compared) is a service of TotalEnergies that provides a complete range of analytical monitoring systems for in-service oils, available for any automotive and industrial application. For management and technical monitoring of mining, construction and transportation vehicles as well as industrial equipment, LubAnac offers a full range of in-depth analysis processes for in-service oil including Membrane Patch Colorimetry.

       

      Failure to correctly implement the required suite of tests for performing extended oil drains of large hydraulic systems will ultimately result in premature failure or malfunction of the hydraulic system. This in turn, can lead to increased component change outs and reduced oil drain intervals thereby negating any potential savings initially achieved through the planned Oil Drain Extensions programs. Put in laymen’s terms, if not managed correctly, the process of Oil Drain Extensions provides a short term gain followed by long term pain of the hydraulic system.

    • Energy use is a major expense in the mining industry.

      Finding ways to lower energy costs reduces total cost of operation, helping mining companies to improve their bottom line.

      Energy use is a major expense in the mining industry.

      Finding ways to lower energy costs reduces total cost of operation, helping mining companies to improve their bottom line.

      The most effective ways to reduce energy costs include:

      • using lighter viscosity grades of lubricants;
      • using synthetic lubricants in industrial gear equipment;
      • high VI viscosity hydraulic fluids;
      • fuel cleanliness;
      • fuel additives.

      TotalEnergies teams have identified how fuel additives help to reduce energy use and costs.

      Additives are often added at the refinery to amend the properties of the base fuel to meet the required specifications at optimal costs.

      These may include additives to adapt cetane property, lubricity, cold flow improvers to meet legislative fuel requirements for a region are met.

      Oil companies may use an additive package at different treat rates customised to improve the quality of the diesel usually used on the market. Such additives are added to the fuel during distribution or at the end users facility.

       

      Combustion process

      The role of an injector in a diesel engine is to atomise fuel, that is, to convert the required volume of “liquid fuel” into many tiny droplets with a size and spray pattern appropriate for auto-ignition combustion.

      Converting this fuel into a “spray” form allows for mixing of the fuel with oxygen to form a combustible mix. A fully functioning injector is required for even engine operation and efficient combustion.

      Any damage or defect to an injector may affect atomisation of the fuel, which reduces the effectiveness of the atomisation process, resulting in lower efficiency of the combustion process.

       

      Injector deposits

      Elevated temperatures at the injector nozzle tip generally propagate external injector deposits. Once initiated, continued build-up of carbonaceous deposits around the injector nozzles is heightened.

      Although these deposits will not usually lead to injector failure, the formation of these external deposits on the injector may impact the quality of the combustion process.

      The effect of injector fuel spray properties is an unseen issue and may go undetected, resulting in power loss, reduced fuel economy and increase in emissions.

      As technology in engines improve, the move to higher fuel temperatures and pressures can also lead to fouling of the internal parts of the injectors, a process known as Internal Diesel Injector Deposits (IDID).

      IDID form on the internal parts of the injector, such as the injector needles and valves. While these deposits can form on any type of injector, recent engine are particularly sensitive to this kind of deposits.

      Fuel additives

      Fuel additives can be categorised as organo-metallic or metal-free additives. Organo-metallic additives are commonly used as octane boosters and anti-knock agents.

      These additives were then introduced into fuels for diesel engines for their ability to further oxidize soot (particulates) from combustion. There are a number of metal additives known to improve or catalyse combustion in diesel engines, including barium, cerium, copper, iron and magnesium. Unfortunately, metallic additives have the tendency to form external deposits.

      These deposits can build-up within the combustion chamber and lead to combustion in-efficiencies, higher fuel consumption and maintenance, resulting in an increase in costs.

      Further, the use of metal-based additives in fuels is not recommended by many OEMs (Original Equipment Manufacturer) of newer technology engines, especially those equipped with exhaust after treatment equipment (diesel particulate filters).

       

      EXCELLIUM products

      TotalEnergies recommends the use of Excellium Concentrate dieselfuel additives, a premium range of products that “cleans” the engine and provides longstanding protection to make the engine more efficient*, more economical* and less polluting*.

      The additive contains no metallic constituents. Therefore, the fuel additive is regarded as ashless in accordance with OEM recommendations and the compliance with local fuel specification is preserved.

      Excellium CONCENTRATE DIESEL enables optimum performance of the combustion process* within the engine to be sustained, thus maintaining maximum power output. The additive is also fully proven for preventing any IDID formation*.

      Excellium CONCENTRATE DIESEL contains deposit control additive technology, reducing deposit build-up up to 93 per cent**. Eliminating carbonaceous deposit formation at the injector nozzle tip* contributes to improve the engine efficiency and then save fuel*.
      Furthermore, the reduction in consumption directly results in a reduction in CO2 emissions.

      The demand for energy will continue to increase as will the need to reduce carbon emissions resulting from this increase in energy usage. Any reduction in the use of hydrocarbons (diesel fuel) as a result of improved combustion efficiency can make significant savings to any company’s bottom line.

       

      *In relation to a non-specifically additized fuel.
      ** In relation to a non-specifically additized fuel, tests performed in June2017 with EXCELLIUM Concentrate Diesel STAR on a diesel engine on a test bench as per reference method CEC F-23-A01. The results may vary with the type of engine.

       

    • Victories are celebrated with TotalEnergies lubricants every day. Thrilling victories, that make our childhood dreams come true. And then there are the everyday victories, those that make us proud of pursuing the challenges we face day in, day out.

      Victories are celebrated with TotalEnergies lubricants every day. Thrilling victories, that make our childhood dreams come true. And then there are the everyday victories, those that make us proud of pursuing the challenges we face day in, day out.

      Today, we will take you behind the scenes and reveal some of the secrets of TotalEnergies lubricants.

      Thanks to their performance, TotalEnergies lubricants remove impurities, protect from wear and corrosion, act as sealing agents and reduce temperature, making for greater output. Lubricants limit friction by facilitating the free movement of multiple-mechanical parts that come into contact with each other.

      In fact, TotalEnergies lubricants alone account for up to 35 % of the engine cooling function.

      For more than 100 years now, TotalEnergies Lubricants has been innovating to extend the lifecycle of your engine by protecting it from wear and corrosion, to reduce fuel consumption thanks to a dedicated Fuel Economy range and to optimise vehicle maintenance costs, through less frequent oil changes.

      By using TotalEnergies lubricants you are taking good care of all the vehicle's key mechanical centres - engine, transmission, brakes, boxes and axles

      … And perform under the toughest operating conditions…

      ... for every market segment: from two-wheeled light vehicles to transport, construction, agricultural equipment, drilling and mining activities, leisure craft, waterways and fishing.

      The TotalEnergies Lubricant range was initially developed for racing and benefits from cutting-edge research. Developed in close cooperation with our automotive partners, they are constantly devolving and increasingly innovative!

      Our lubricants are approved and recommended by a large number of vehicle manufacturers and are suited to all their vehicles. For now and in the future, TotalEnergies Lubricants is committed to developing a range of products that comply with environmental standards, are energy efficient and reduce emissions of CO2.

      Our performance is measured on race tracks around the world but driven to higher standards every day by you.

    • The metal parts of your engine suffer the effects of friction as they rub together. This generates heat and leads to premature wear. It's a bit like water-skiing. The buoyancy of the water helps you to glide across the waves more easily. The same principle applies to a lubricant inside your engine.The lubricant helps to reduce the effects of friction between the moving parts. As a result, they wear out more slowly and do not heat up.The oil reduces the amount of friction, which improves the performance of the engine and also reduces its fuel consumption.

      But that's not all. Your lubricant protects your engine against corrosion and acid attacks. It also helps to reduce the temperature of your engine.

      What is a lubricant

       

      The metal parts of your engine suffer the effects of friction as they rub together. This generates heat and leads to premature wear. It's a bit like water-skiing. The buoyancy of the water helps you to glide across the waves more easily. The same principle applies to a lubricant inside your engine.The lubricant helps to reduce the effects of friction between the moving parts. As a result, they wear out more slowly and do not heat up.The oil reduces the amount of friction, which improves the performance of the engine and also reduces its fuel consumption.

      But that's not all. Your lubricant protects your engine against corrosion and acid attacks. It also helps to reduce the temperature of your engine.

      Finally, it removes any impurities that may accumulate over time (soot, dust and wear debris), which maintains the performance level of your engine.

      Your lubricant is generally composed of 70% base oil and 30% additives.

      The additives provide essential properties:

      The antioxidant additives increase the oil's ability to resist high temperatures, which results in less frequent oil changes.

      Other additives maintain the lubricity of the oil.

      The detergent additives prevent the formation of deposits, which keeps the engine clean and maintains its performance level throughout its lifetime.

      The anti-foaming additives prevent the oil from frothing and stop the oil pump from running dry.

      The cold temperature additives help the lubricant to remain fluid at low temperatures, allowing the engine to start more rapidly.

      The anti-wear additives increase the longevity of your engine by creating a protective barrier on the surface of the parts.

      The extreme-pressure additives increase resistance to wear and reduce friction.

      Finally, the anti-corrosion additives prevent acid, water and air from attacking the different metal parts. This means that your engine remains younger for longer.

      So now you know everything there is to know about the role of lubricants and their additives.

    • Most people overlook checking engine oil. It’s easy to do, but can cause major damage requiring thousands of dollars of repairs. You need to check motor oil before any long trip to avoid major damage. In case of use for work, we recommend that you check your oil level daily.

      Checking car oil is quite easy

      We recommend that you check the oil level in the morning when the engine is cold and most of the oil has run down into the engine’s oil pan. The oil pan forms the bottom of your engine and is the reservoir for the engine oil. You will need a clean cloth or paper towels , a can of oil and a funnel. We also recommend wearing disposable gloves. Use only the recommended oil for your engine. Find the right QUARTZ engine oil for your engine at https://lubricants.totalenergies.com/consumers/our-added-value/answer-your-needs/cars

      Most people overlook checking engine oil. It’s easy to do, but can cause major damage requiring thousands of dollars of repairs. You need to check motor oil before any long trip to avoid major damage. In case of use for work, we recommend that you check your oil level daily.

      Checking car oil is quite easy

      We recommend that you check the oil level in the morning when the engine is cold and most of the oil has run down into the engine’s oil pan. The oil pan forms the bottom of your engine and is the reservoir for the engine oil. You will need a clean cloth or paper towels , a can of oil and a funnel. We also recommend wearing disposable gloves. Use only the recommended oil for your engine. Find the right QUARTZ engine oil for your engine at https://lubricants.totalenergies.com/consumers/our-added-value/answer-your-needs/cars

      How to check your car oil

      • Step 1: Put your car on a level surface and turn the engine off. Make sure the engine is cool.
      • Step 2: Lift the hood and secure it.
      • Step 3: Locate the dipstick: it’s usually a color that stands out (often yellow, red or white). If you can’t find it, check the owners’ manual.
      • Step 4: Check the engine oil With a towel, take the dipstick out, wipe it clean and check the high and the low marks at the tip of the dipstick. The dipstick is immersed in the oil in the oil pan.

      How to check motor oil level. Reinsert the dipstick, pull it out and check the oil. If your engine oil level is below the low mark, you’ll have to add more. Do not fill up over the maximum level.
      Even if your oil is black, it may still deliver the required performance.

      How to top up your oil:

      • Put the dipstick back, being careful that it does not touch anything and pick up engine dirt.
      • Remove the oil filler cap, normally located on the top of the engine. If you cannot find it, check your owner’s manual.
      • Use a clean funnel. If you can’t, turn the container upside down.
      • Pour in the amount necessary.
      • Put the cap back on.
      • Recheck the level to make sure it is below the maximum level. Overfilling can damage the catalyst. Start with a small amount and repeat the procedure as necessary.

    • Just like your engine needs oil to lubricate the different components and protect them against wear and corrosion, your transmission is as well lubricated by special fluid called transmission fluid.

      Maintaining the proper transmission fluid level is important to keep your transmission shifting properly and your car running smoothly.

      How do I check my transmission fluid?

      Just like your engine needs oil to lubricate the different components and protect them against wear and corrosion, your transmission is as well lubricated by special fluid called transmission fluid.

      Maintaining the proper transmission fluid level is important to keep your transmission shifting properly and your car running smoothly.

      How do I check my transmission fluid?

      • Step 1: Check your owner’s manual. Do you have a manual or an automatic transmission? Manual transmissions don’t usually have a dipstick. They are factory filled. No top-up is needed. The fluid only has to be changed in the event of repairs.
      • Step 2: Locate the transmission dipstick if you have an automatic transmission. The transmission fluid dipstick is usually red (yellow or white for the engine oil dipstick). The owner’s manual will help you to find the dipstick. If you're lucky, it will be labeled
        - On rear-wheel drive vehicles, the dipstick is usually on the passenger side of the engine compartment, near the back of the engine.
        - On front-wheel drive vehicles, the dipstick is usually on the driver’s side, on one side of the transmission. If you don’t find it, your owner’s manual should show you where to look for it.
        Many cars don’t have a transmission dipstick. The oil level may have to be checked using an electronic device or by removing a screw in the transmission housing. Checking fluid levels in a sealed transmission is a much more complicated process. The average car owner does not have the skills required to check the transmission fluid level. If your car doesn’t have a dipstick have your local transmission shop or dealership check the level. A good time to do this is while you’re having the engine oil changed
        If your car has a transmission dipstick, you should check the transmission fluid level regularly.
      • Step 3: How do you check transmission fluid? or How to check transmission oil
        Remove the stick, wipe it with a clean cloth, reinsert it, leave it in for 5 seconds, then pull back out and check. Add fluid if necessary. Always use the fluid recommended by the manufacturer.
        Add only a little at a time, checking the level with the dipstick each time. It's easy to add transmission fluid, but fairly difficult to remove it if you add too much.
        If the transmission requires more than a quart or is using fluid regularly, take your car in to have it checked for leaks.

      How to properly check transmission fluid. You can also check the color and smell.
      Color is very important for transmission oil. It should not change from its normal light brown, semi-transparent appearance. Automatic transmission fluid (ATF) is a cherry red. If it is dark red or brown, you should have your fluid changed

      If it smells burned or has particles in it, you should also have your transmission serviced. What is a transmission service? It consists of changing the transmission fluid filter before adding the transmission fluid.

      Impress your family when they ask you how to check your transmission fluid or how do you check transmission oil.

    • For transmissions with a dipstick, the procedure is the same as described for normal transmission fluid.
      Many Fords, Toyotas, GMs and other vehicles no longer have an automatic transmission dipstick for checking the fluid level. Automakers are eliminating automatic transmission dipsticks. Newer transmissions are far more complex than older models and the transmission fluid levels are far more critical. Special procedures are required to check the automatic transmission fluid level in these models.

      What is automatic transmission fluid?

      Automatic transmission fluid (ATF) is the fluid used in vehicles with automatic transmissions. It is usually red or green.

      Why check the automatic transmission fluid level?

      Automatic transmission fluid is the lifeblood of the transmission. The fluid produces the hydraulic pressure needed to operate the transmission. It also cools and lubricates the transmission. When the fluid level is low, the pump may draw air into the system. Air in the hydraulic system interrupts the proper flow of automatic transmission fluid. Damage can occur very quickly when transmission fluid is low.

      How to check automatic transmission fluid level?

      For transmissions with a dipstick, the procedure is the same as described for normal transmission fluid.
      Many Fords, Toyotas, GMs and other vehicles no longer have an automatic transmission dipstick for checking the fluid level. Automakers are eliminating automatic transmission dipsticks. Newer transmissions are far more complex than older models and the transmission fluid levels are far more critical. Special procedures are required to check the automatic transmission fluid level in these models.

      If you want to go further, learn how to change automatic TRA

      1. Drain the transmission fluid: First, disconnect the cooling line running from the transmission to the radiator. Connect a piece of rubber tubing to the pipe and place the free end of the tube in an empty container. Start the engine and let it idle. Transmission fluid should flow out of the cooling line and into the container. As soon as the fluid stops flowing, turn off the engine. You can then reconnect the cooling line to the radiator.
      2. Remove the bolts holding the drain oil pan to the bottom of the transmission.
      3. Clean the drain pan with transmission fluid.
      4. Replace the filter.
      5. Replace the gasket.
      6. Replace the pan: Once the filter and gasket are in place, put the pan back on the transmission. Hand-tighten the bolts for the first few turns so that you don't strip the threads. Then use a torque wrench to finish tightening the bolts. Do not to overtighten the bolts or you will damage the threads in the transmission and dent the pan.
      7. Fill with automatic transmission fluid: Dexron III ATF is the most common, but refer to the owner's manual to choose the appropriate automatic transmission fluid. Check the amount as well.

    • Start by checking that your lubricant matches the manufacturer’s recommendations. Check the owner’s manual for more details. Gently unscrew the cap of your tank to add some oil. Check the oil level again, and repeat several times until the oil has reached the maximum mark, without going over it, then put the cap back on your tank.

      It’s now safe to drive! We look forward to giving you more lubricants advice in the future

      You’re wondering why you need to top-up your oil. Basically, it extends the life of your engine by protecting it from wear and tear that can’t be repaired. The above video explain you how to top up your oil, which needs to be done every 2000 kilometers

      Step one: Check your engine’s oil level

      You’ll need some gloves, kitchen paper and a funnel. Make sure your vehicle is on a flat surface

      Your engine still needs to be warm and switched off for a minute

      To check your oil level, pull out the rod which is normally yellow or orange and located near the engine

      Pull it out as far as it will go, then put it back in its tube. Wait a few seconds before taking it out to check the oil level. The minimum and maximum levels are marked at the end of the rod. If the level is below the minimum mark, top-up your oil immediately. Most vehicles have a warning light on the dashboard. If this light is yellow or red, you need to stop as soon as you can to check your oil level and top it up if necessary.

      Step two: Top-up your oil

      Start by checking that your lubricant matches the manufacturer’s recommendations. Check the owner’s manual for more details. Gently unscrew the cap of your tank to add some oil. Check the oil level again, and repeat several times until the oil has reached the maximum mark, without going over it, then put the cap back on your tank.

      It’s now safe to drive! We look forward to giving you more lubricants advice in the future

    • Keep your used motor oil in a clean, leakproof container like a plastic jug or bottle. Make sure the cap is tightly sealed and store in a cool, dry place away from heat, sunlight, children and pets. Used motor oil can't be recycled if it's mixed with other liquids like antifreeze or brake fluid.

      Most people don’t know that used motor oil can be recycled.

      How to safely dispose of oil

      Keep your used motor oil in a clean, leakproof container like a plastic jug or bottle. Make sure the cap is tightly sealed and store in a cool, dry place away from heat, sunlight, children and pets. Used motor oil can't be recycled if it's mixed with other liquids like antifreeze or brake fluid.

      Where to dispose of oil and oil filters

      Where can you take your used motor oil and oil filter to dispose of them? Many auto parts stores and some service stations will take used motor oil and oil filters for recycling. We collect used oil as well, so you can also call our sales manager, who will advise you on the best option. Don't put it out with your normal trash!

    • You're about to change your oil, and you're wondering which of the lubricants available on the market you should choose. It's really a choice that depends on your vehicle.

      The right lubricant will meet international standards (ACEA, API, ILSAC, JASO), as well as the specifications of each manufacturer.(ex: Renault RN0710, PSA B71 2290, BMW LL-04….)

      To make your choice, first check your vehicle's maintenance manual to find the standard or authorized lubricant recommended by the manufacturer. This should match the information on the back of the prod1uct.

      You should also choose a lubricant whose viscosity matches your vehicle's needs. Viscosity is a measure of resistance to free flow, and is listed in two grades: a cold grade and a hot grade.

      TotalEnergies Lubrifiants offers high-performance lubricants on the market. For example, Low SAPS lubricants avoid particle filter clogging, thereby protecting your engine's longevity. Particles are captured and burned in a particle filter, significantly reducing the amount of particles emitted into the air.

      There are also Fuel Economy lubricants from the Quartz product line that help significantly lower your fuel consumption.

      When should you change your oil? Oil change frequency should be based on several factors: the manufacturer's recommendation, generally listed in km or in years, and the kind of driving you do most often: city, rural, or highway. You can always visit a nearby TotalEnergies shop for more advice.

      You're about to change your oil, and you're wondering which of the lubricants available on the market you should choose. It's really a choice that depends on your vehicle.

      The right lubricant will meet international standards (ACEA, API, ILSAC, JASO), as well as the specifications of each manufacturer.(ex: Renault RN0710, PSA B71 2290, BMW LL-04….)

      To make your choice, first check your vehicle's maintenance manual to find the standard or authorized lubricant recommended by the manufacturer. This should match the information on the back of the prod1uct.

      You should also choose a lubricant whose viscosity matches your vehicle's needs. Viscosity is a measure of resistance to free flow, and is listed in two grades: a cold grade and a hot grade.

      TotalEnergies Lubrifiants offers high-performance lubricants on the market. For example, Low SAPS lubricants avoid particle filter clogging, thereby protecting your engine's longevity. Particles are captured and burned in a particle filter, significantly reducing the amount of particles emitted into the air.

      There are also Fuel Economy lubricants from the Quartz product line that help significantly lower your fuel consumption.

      When should you change your oil? Oil change frequency should be based on several factors: the manufacturer's recommendation, generally listed in km or in years, and the kind of driving you do most often: city, rural, or highway. You can always visit a nearby TotalEnergies shop for more advice.

       

    • 6 WAYS TO DECREASE THE OIL COST ON A MINE SITE

      TotalEnergies' mining specialists are always looking for ways to help our customers reduce their controllable costs. They have put together 6 practical tips for mining companies to make savings on mine sites. It is simple and it’s worked for many of our mining clients, we hope it helps you as well!

      1/ Rationalize your oil

      A core fundamental of oil management is to rationalize the number of lubricants and lubricant packaging. The TotalEnergies mining team has observed that this can result in savings up to 17 % of your total oil cost! This is done through savings in physical inventories, costs associated with handling, spoilage, theft, storage space and stock obsolescence.
      Quite often we find two or three oils covering similar applications, with slightly different specifications or pack sizes.

      One way in which TotalEnergies can help is to go through your oil range at site and select the most appropriate product to cover as many applications as possible. For example TotalEnergies has developed the TP Star Max lubricant which is suitable for engine, hydraulic and transmission systems thus reducing the need to store 3 different oils on site whilst still meeting the required OEM specifications.

      2/ Standardize your oil packaging

      Another way is to standardize your oil packaging wherever possible: Do you really need the same product in pails, drums, Intermediate Bulk Containers (IBC’s) and bulk? Too many options can result in increased costs and duplication of effort. A thorough look at where and how each pack size is being used and dispensed will allow you to reduce the number of disposable packs. Not only will you simplify your ordering processes, but you will also free up valuable storage space and reduce your cost of working capital.

      3/ Avoid Contamination

      Contamination control is often overlooked when considering why premature failure occurred or why oil life has been diminished. The two primary contaminants in oil are dirt (environmental dust) and moisture. When oil is contaminated, it accelerates wear which can result in early breakdown, thus leading to significant increase of the operating cost.

      Thus, maintaining clean oil is a key investment initiative for mining companies.
      TotalEnergies suggests using contamination control techniques such as desiccant breathers on bulk and intermediate containers as well as filtration on bulk fluid dispensing. The use of filtration on fluid dispensing on IBC and Drums can also be applied.

      The benefits of sound contamination control in lubricants will extend the life of lubricated equipment and reduce overall maintenance costs.

      4/ Get your used oil analyzed

      The aim of oil analysis is to get a “snap shot” of the condition of both the lubricant and the equipment at a point in time. Used over a period of time, used oil analysis allows predictive maintenance which helps you to know when to plan your maintenance operations at the optimal moment. It also allows you to optimize your oil change frequency, to avoid costly emergency repairs, and to increase lifespan of your machines.

      For example TotalEnergies LubAnac Laboratories perform over 200,000 diagnostics each year for mining companies and other automotive and industrial customers. All that is required is to collect the oil sample at regular intervals (without having to stop the machine!) and send it to TotalEnergies' oil analysis laboratory using the LubAnac analysis kit. LubAnac automatically sends a full comprehensive report via email with the analysis of the sample. This report can also be viewed over the internet.

      Contact TotalEnergies to find if there is an LubAnac lab in your region.

      5/ Get a FIFO approach with the storage of your oils

      When a 205 litre container or a 1000 litre container (IBC) has reached the end of its product shelf life, its use can have detrimental effects on your equipment. The product should be discarded which comes with increased cost. This can be attributed to the term “obsolescence cost” and it occurs when proper storage practices are not in place.

      TotalEnergies suggests a First-In-First-Out (FIFO) approach to storage of oils on mining sites. Improving overall warehouse management of stored products as well as a FIFO approach to product storage will help reduce these obsolescence costs.

      TotalEnergies' site facility audit can help identify areas of improvement.

      6/ Get the lube supplier to audit the mine

      TotalEnergies employs oil specialists to assist TotalEnergies' clients in identifying areas of improvement that contribute to cost saving initiatives.

      For example, replacing just one lubricant with another can contribute to the reduction of many different types of costs. These may include:

      • Purchasing cost,
      • Maintenance cost
      • Energy cost
      • Fuel cost
      • Waste oil cost

      Contact TotalEnergies Mining Solutions team today to find out more.

    • Oil consumption is determined by engine power output and fuel consumption. This means that your engine will consume more oil when you are driving a sportier car or faster or with a trailer to transport horses or boats. Whenever you notice that your vehicle is consuming more oil than before under the same conditions of use, you need to find out why this is happening. High oil consumption can create air pollution and can affect after-treatment devices such as particulate filters and catalysts.

      Oil consumption is determined by engine power output and fuel consumption. This means that your engine will consume more oil when you are driving a sportier car or faster or with a trailer to transport horses or boats. Whenever you notice that your vehicle is consuming more oil than before under the same conditions of use, you need to find out why this is happening. High oil consumption can create air pollution and can affect after-treatment devices such as particulate filters and catalysts. Below, some reasons for higher oil consumption:

      • Abnormal piston ring and cylinder wear.
      • Defective crankcase ventilation.
      • Worn valve seals.
      • Abnormal turbocharger wear.

      This listing is not exhaustive. There are plenty of reasons why your oil consumption may be high. We recommend that you see a qualified mechanic.

    • 5 WAYS TO REDUCE FUEL COSTS AT A MINE SITE

      In the current climate of low commodity prices, many mining companies are under increasing pressure to reduce operating costs. The most obvious way to cut costs on fuel is to look for price reductions, but with the competitive nature of supplying to mines there is most probably very little margin left to “squeeze” out of the suppliers. 

      There have also been some exciting technological advances in recent years with fuel economy improvements being realized through improved engine design, turbo chargers, Electronic Fuel Injection etc. 
       
      Assuming that you have the best price you can get from the suppliers and the most economical equipment for your site, there are few other areas you can look at to reduce fuel costs and fuel consumption in your mining operations.

      Below you will find five suggestions on how to further reduce your overall fuel consumption.

       

      1. Use lighter viscosity engine oil

      The development and shift to lighter grade SAE 10w30, and SAE 5w30 oils in favour of SAE 15w40 grade engines oils plays a significant role in reducing fuel consumption. The lower viscosity oil effectively means reduced friction under hydrodynamic conditions within the engine. Less friction means less fuel consumption. 
       
      TotalEnergies' range of FE lubricants play an essential role in reducing the operating fuel costs for mining companies by utilizing specific viscosity grades and specially enhanced additives designed to minimize the friction responsible for 10-15% of energy loss within an engine and drive train compartments.

       

       

      2. Make sure your hydraulic fluid is of high quality

      High quality, high Viscosity Index (VI), multi-grade hydraulic fluids work by reducing hydraulic leakage of the hydraulic pump through the broader operating temperature range. This means that at higher operating temperatures the viscosity of the lubricant is not as thin when compared to a lower VI mono grade hydraulic oil of similar viscosity. This equates to less engine power needed, (and less fuel), to deliver the required fluid power to the working parts of the hydraulic system under operating conditions. Following similar principles, higher equipment productivity is also realized.

       

      3. Improve your fuel cleanliness

      Particulate contamination of diesel fuel due to in-efficient housekeeping practices has the propensity to reduce filter life, diminish fuel life and cause component failures. 
      The unwanted particulates in diesel fuel can serve to increase fuel pump wear. In addition, due to the high fuel pressures, these particulates can act as a projectile within the fuel system leading to increased injector nozzle wear and reduced combustion efficiency, which in turn results in increased fuel consumption. Improvements in fuel cleanliness will also improve fuel pump and injector life (reduced maintenance costs).

       

      4. Use Excellium (fuel additive)

      Many diesel fuel researchers conclude that there is benefit from the use of chemical related supplementary fuel additives. 
      Excellium diesel fuel does not increase the combustion efficiency of the fuel during the combustion process but rather prevents (and even reduces) the formation of carbonaceous deposits at the injector nozzle tip which in turn helps optimise the combustion process. This is where fuel savings are then realized. Excellium diesel fuel enables optimum performance of the combustion process within the engine to be sustained.

       

      5. Other cost saving ideas

      There are other energy and cost reduction projects to consider the likes of which include but not limited to:

      • Periodic bench mark testing or requests for tenders from fuel suppliers
      • Lubricant rationalisation programs and consideration to reducing inventory levels 
      • Use of a Fuel Management System to help identify in-appropriate use of diesel fuel on site 
      • As your supplier to perform oil drains extention programmes
      • Use energy efficient lubricants 
      • Follow the link to find more ways to reducing cost on a mine site. 

      Contact TotalEnergies experts to find out more.

       

       

       

    • DO YOU HAVE THE RIGHT DILUENT IN YOUR METAL EXTRACTION PLANT?

      Solvent extraction is now the preferred route for extracting metals from ores and other sources as it ensures both environmental responsibility and cost efficiency. In order to ensure optimal performance in terms of operator safety, process efficacy and reliability there a few key things to take into account when choosing the best extraction fluid for your liquid-to-liquid extraction processes.

      The aim in all operating plants is to create a safer working environment with stable products that have a high flash point as well as a fast disengagement phase. Here are three points to consider when choosing your diluent.

       

      1. Lower the aromatic content of your diluent for operator’s comfort and health

      Diluents commonly used in solvent extraction processes have an aromatic content of around 15%. Operators who work daily in mining extractions plants often complain of the heavy smell of diesel type products. By switching to Low Aromatic diluents you enable the operators to work in an odor free environment, which leads to much better working conditions.

       

       

      2. Ensure that your extraction efficiency is not impacted

      In the solvent extraction process it is the combination of extractant and diluent which impacts the extraction efficiency performance. It has been shown in numerous field trials by mining companies that the extraction efficiency is not impacted by using low aromatic diluents. A beneficial aspect that can be noticed when you use low aromatic diluents is that you have less crude formations that are associated with a high aromatic diluents which in turn can trigger the degradation process through oxidation leading to this crude formation. You can quite easily test this in your own lab facility!

       

      3. Choose the correct diluent solution for your mining conditions

      Climate can play a large role in your diluent’s performance. When your operations are faced with weather conditions close to 0°C, or close to 50°C, then you need to consider that the parameters that affect the viscosity and flash point of your diluents will be compromised. A lower viscosity will be key in cold temperatures, whereas a resistance to evaporation, known as the products flash point, will be key in hot areas.
      TotalEnergies' Special Fluids division offers a range of several diluents across a full range of viscosities and flashpoints allowing you to choose the solution best adapted to your operating conditions.

      Contact TotalEnergies experts to find out more.

    • SHOULD OIL ANALYSIS FORM PART OF YOUR MAINTENANCE STRATEGY?

      Maintenance Strategies and Practices have been around for many years. Early maintenance practices of “when it breaks we’ll fix it” has progressed to preventive, predictive and even proactive maintenance strategies. A number of articles also make reference to World Class Maintenance but no one is really sure what this actually looks like. Identifying the correct maintenance strategy for your equipment can reduce overall operational costs as well as add significant value to your mining operations.

       

      4 Maintenance strategies

      The 4 main maintenance strategies can be simply described as:
      Breakdown maintenance – basically, fix or repair the equipment when it breaks
      Preventive (routine) maintenance – the service, replacement or overhaul of the equipment at predetermined intervals according to a defined set of criteria with the aim of avoiding unwanted failures
      Predictive maintenance – identified maintenance activities incorporating condition monitoring techniques (such as Oil Analysis), preventive maintenance and equipment test measurements aimed at making informed decisions as to the overall health of the asset and any associated risk.
      Proactive maintenance – the use of both preventive and predictive strategies for improving equipment reliability by identifying root cause of failure and utilise engineering solutions to address the root caus

      Choosing the correct maintenance approach for your mining operation

      As in most cases, there are pros and cons with each type of maintenance strategy. The best approach is to identify the most cost effective maintenance strategy based on risk and cost of the asset, the risk and consequences in the event of a failure, and how both of these relate to your company’s goals. Each piece of equipment should be reviewed, assessed and treated on its own merits

      A breakdown maintenance strategy, (that is to only repair the equipment when it breaks down), is sometimes applied to equipment that if a failure occurs, has minimal disruption to production, is relatively cheap, is quick to replace and will have no impact to safety. Some equipment, such as an excavator, can be identified as critical to your operations and where a breakdown or failure is extremely costly to the company. This could be due to production downtime or a long replacement time, or where safety may be compromised. When it comes to these critical pieces of equipment the maintenance strategy that should be applied would be predictive or proactive so as to reduce the possibility of failure, thereby ensuring maximum value from the equipment.

       

       

      What is Oil Analysis?

      Oil analysis is a condition monitoring tool that involves taking approximately 100 millilitres of oil taken from an oil wetted compartment while it is in use and subjecting it to a variety of chemical and physical tests. In the case of used oil, these tests provide a snap shot as to the current health of the asset, the general health of the oil and any contamination issues that may exist. The practice has proven to be a very successful and cost effective condition monitoring technique for companies that operate large intensive capital equipment (Mining equipment, Construction equipment, Industrial equipment etc).

      Into which Maintenance Strategy does Oil Analysis belong?

      Oil Analysis as a conditioning monitoring tool has one foot each in predictive and proactive maintenance strategies. The results from the oil analysis can be used as a predictive tool for identifying adverse wear trends and their likely causes such as coolant leaks, fuel dilution or environmental dust entry issues etc. The information from the oil analysis results can then be used to aid in planning and performing appropriate maintenance activities that will reduce the total operating costs arising from premature equipment failures, as well as to optimize oil usage through oil drain extension programs.

      In addition oil analysis can assist in identifying whether proactive strategies such as improvements in filtration have achieved the cleanliness (ISO code) target. It can also be used to establish if changes in the maintenance activities have had the overall desired effect of generating equipment improvements over past performance.

      When is oil analysis used incorrectly?

      Unfortunately, there are many occasions where oil analysis is used on an ad-hoc basis, such as a yearly sample on a main conveyor gearbox, or after a failure. Whilst this could be used to provide a once off indication as to health of the oil and the amount of contaminants that has accumulated in the oil since the last oil change, it cannot be used to ascertain overall equipment health or performance. This type of practise leads to little or no value being realised from this very useful condition monitoring technique.

      On other occasions, Oil Analysis may be viewed as the work management tool to drive work maintenance activities rather than using the results as a tool to assist in work maintenance practices. This strategy should not be viewed too favourably either as Oil Analysis does not cover every technical angle. The point is not to confuse a condition monitoring tool as the main driver for maintenance activities. Rather, it should be used to compliment maintenance procedures and allow for forward planning.

      How often should you take an oil sample?

      To get the best information from ones oil analysis program, one must take oil samples in the same manner and at the same identified scheduled intervals, continuously over an extended period. The ideal oil sampling period will vary depending on the identified criticality of equipment. If the maintenance strategy has been identified as predictive or proactive, then the associated oil analysis sampling regime established may be to sample the equipment/compartment every 250 or 500 hours. The benefits of regular oil sampling and analysis thereof to mining operators for the purposes of predictive and proactive maintenance include:
      Monitoring wear (Iron, Chromium, Copper etc) trend deviations
      Identifying any contamination issues early (dirt, moisture)
      Confirming health of the lubricant (extend or drain the oil)
      Evaluating effectiveness of filtration upgrades or changes in maintenance activities

      With this information one is able to monitor the equipment condition over a regular and prolonged period which helps identify potential failures before they occur.

      If you feel that your mine can benefit from Predictive or Proactive maintenance using oil condition monitoring, then please contact TotalEnergies Mining Solutions. You can also access more information at https://miningsolutions.totalenergies.com/faq

      TOTALENERGIES' approach to Oil Analysis

      Because it is crucial for mining companies to have access to reliable oil analysis laboratories, TotalEnergies views its LubAnac oil analysis program as an integral service to its clients.

      To find out more about oil analysis and how TotalEnergies' LubAnac service can add value to your operations, visit LubAnac.

    • YOU HAVE DECIDED TO CARRY OUT REGULAR OIL SAMPLING – NOW WHAT?

      A question that is quite often debated by maintenance engineers is “Should oil analysis form part of your maintenance strategy?”  (Follow the link to read the first article in this series explaining this).

       

      Following on from the first article in the series, it is fair to say that used Oil Analysis forms a core element of a Predictive or Proactive maintenance program and if applied correctly has the following benefits:

      • provides extension in equipment life,
      • helps provide peace of mind when extending  oil drain intervals, 
      • reduces failures and failure rates, 
      • decreases  maintenance costs
      • increases equipment reliability,

      all of which contribute to supporting and sustaining cost reductions at a mine site. 

      An Equipment Lubrication Audit is generally the starting point of a wider detailed site audit which provides support with contamination control (housekeeping) and maintenance programs.  The audit should also include identifying those pieces of equipment which are critical to mining and earth moving operations and would benefit most from a condition monitoring program where the use of Oil Analysis ensures the maximum benefits are achieved.  This is where TotalEnergies' Mining Solutions (TMS) team can assist. As your lubricant supplier they will provide a detailed site audit, lubricant survey and assist with sampling programs. Follow the link to find out How TotalEnergies  Mining Solutions team help mining companies reduce their costs. 

      Consolidating your Oil Analysis program with one service provider

      Once you have decided that you are committed to including Oil Analysis as part of your condition monitoring program, the next step involves selecting the preferred Oil Analysis service provider. Often, there will be more than one service provider’s sample bottles to select from at a mining or construction site. This may be due to the Original Equipment Manufacturers offering their laboratory services as part of their warranty program, as well as other independent service providers used for other equipment. This could lead to having a number of different service providers on one site each with their own separate procedures which increases not only the risk of the oil sample going to the wrong laboratory, but in addition the added effort of trying to understand and get to grips with the different report layouts and report delivery systems from each of the service providers.

      This approach is by no means efficient especially for those tasked with managing the Oil Analysis program on site and therefore TotalEnergies recommends that where possible consolidate your Oil Analysis program with one service provider. 

      What you should be looking for from your laboratory

      For Oil Analysis to be effective and provide valuable information to the maintenance and reliability teams, the laboratory must produce sample results that are both timely and accurate. Laboratories that are selected to perform the used Oil Analysis service must also be capable of providing fuel, coolant, grease and other non routine type testing in an appropriate manner and time frame. 

      Every customer looks for 3 main criteria from their Oil Analysis service provider:

      1. Quality of results
      2. Excellent processing (turnaround) time
      3. “Best possible price”

      Unfortunately, you will invariably only be able to receive two out of the three above. Decide early on which two are most important to you and which are most needed for your operations.

      Assess your service provider (laboratory) for the following criteria:

      • Do they have the correct Quality accreditation?
      • Do they have the ability to perform more than just routine testing”
      • Are their turnaround times acceptable?
      • Is the sample submission process easy?
      • Check the experience and competence of their  laboratory staff 
      • Check the experience and expertise of their data Interpreters

      To satisfy all of these needs TotalEnergies Lubricants provides LubAnac, an oil analysis service that provides a complete range of analytical testing and monitoring systems for in-service oils that is easy to use.
      Click to find out more about LubAnac. 

      The Output is only as good as the Input

      Far too often oil samples are sent to the laboratory without all of the required information being recorded on the sample bottles. An often heard complaint is where a site has received 2 or 3 different sets of historical test data for the same piece of equipment. (One reason for this mix-up  is due to the fact that on one occasion only the unit ID may have been supplied to the laboratory, and on another occasion only the serial number. The laboratory has no way of knowing the link between Unit ID and Unit serial number unless an equipment list has been properly drawn up and provided to the laboratory at the onset). 

      Before you embark on this process, it is best to ensure that all equipment and compartments to be included in the oil analysis program have been properly identified. This includes information such as;

      • unit make and model details, 
      • compartment make and model details, 
      • compartment oil capacity, 
      • oil manufacturer, 
      • type and grade of lubricant. 

      An example of the requirements has been provided below for Heavy Mobile Equipment (HME). 

       

      Example Unit Equipment List

      This will reduce the amount of duplication that can occur during the running of the oil sampling program, especially if the sample submission form is written by hand. As indicated earlier, a well detailed lubricant survey provided by your lubricant supplier can go a long way to assisting with this process.

      To assist with this process most laboratories now offer an online sample submission process. This allows the user to complete the sample submission process online, print labels containing the appropriate information and attach the label to the relevant sample bottle. The online submission service has significantly reduced the possibility of duplicate historical data for an individual unit and compartment. A detailed equipment list also ensures accurate selection of equipment when utilizing the online submission service.

      This technical support is provided by the TotalEnergies Mining Solutions team as part of its Lubrication Audit and service for its customers. Please follow the link to find all services provided by TotalEnergies for mining companies. 

      What types of oil tests should I ask for?

      Two other challenges in implementing used oil analysis within the mining industry include;

      • The sampling and processing of used oil analysis technology which is often misapplied; 
      • Wrong tests specified or heavy dependence placed on individual laboratories to make condition assessments.

      From a laboratory perspective one can separate tests into what are called routine tests and non-routine tests. Not every test is applicable for every compartment type, for example, one would not request to check for fuel dilution in a conveyor gearbox. 

      These routine tests comprise primarily of:

      • Spectrometic analysis (elements such as Iron, Lead and also additive elements such as Calcium and Phosphorous are determined from the test)
      • Viscosity
      • Infra-Red (FTIR)
      • Ferrous debris or PQ
      • Cleanliness (Hydraulic compartments) 
      • TAN / TBN

      The laboratories will then group a combination of applicable routine tests to make up a suite of tests (or test package) for each compartment type, such as the groups provided below.

      Example Routine Test Suite for compartments

      Whilst a routine suite of tests provide valuable information, these routine tests may not always provide the whole picture as to asset or lubricant health. For example, in the case of a turbine system, a standard set of routine testing should be applied monthly, but approximately every 12 months additional tests need to be carried out. 

      In the case of the turbine system, the non-routine tests would include:

      • Rotating Pressure Vessel Oxidation Test (RPVOT)
      • Foaming characteristics
      • Water separability

      This then allows for a more informed decision to be made as to the overall health of the oil. There are hundreds of non routine tests that can be requested depending on the information required and TotalEnergies can guide you on what is needed. 
       
      Once the equipment to be tested has been determined, and the required tests and test suite per compartment have been identified, then the sampling process can begin with subsequent samples dispatched to the preferred service provider for testing purposes. 

      TotalEnergies LubAnac oil analysis program

      TotalEnergies Lubricants views its LubAnac oil analysis program as an integral service to its clients. The LubAnac analytical service has been shown to provide great value in predicting and extending component and oil life in earth moving equipment.

      Follow the link to find out more about how TotalEnergies' LubAnac service can add value to your operations.

      The next article in this series will focus on how to utilize the oil analysis results more effectively.

      With decades of reliable supply and value added services to its clients, TMS has become the partner of choice to mining companies. Today, TotalEnergies supplies fuel, lubricants and associated services to over 200 mining sites in over 40 countries.