FUEL CONSUMPTION OF CONSTRUCTION EQUIPMENT

Fuel plays a fundamental role within construction industry. Diesel is used as fuel in most of
construction equipment operation. It contributes more then 30 % of operational costs of
construction equipment, the fluctuation of the price of fuel and fuel consumption have a major
impact on the profits of the company. Hence, implementation efficient fuel management
program is must for reduction in operational cost of construction equipment.

To counterbalance this situation some companies are creating a surcharge to deal with the
ups and downs of fuel pricing or estimating construction cost with higher diesel consumptions.
However, this can be a risky decision because it will increase substantially construction costs.

Diesel is also the most highly influential item in the construction industry that affects all
supplies, material and labor costs.

To stand in competitive market scenario, constant improvement in way of planning, execution

and monitoring are increasing in intensity. On the other hand, this competition of business
presents great opportunities and challenges for the capital-intensive industries like
construction industry for innovative solution.

Construction industry is having no control in cost of diesel, but there is possibility of reducing
in consumption of diesel. We need to look to innovative solutions, go back to basics and re-
invent the way construction equipment is being maintained and operated.

We need to put extraordinary care in use to counterbalance these issues, we need to deploy,
monitor and improve skill maintenance and operational crew for construction equipment
management. This will help in reduction in fuel consumption of construction equipment.
So, how this affect construction industry? Quite simply,

Project cost + Profit = Market price

However, under the present scenario where all are facing the domestic and global
competition, the above definition does not hold good & simply got transformed into:

Market prices - Project Cost = Profit

Although both equations mathematically look to be the same, the difference is obvious as in
the present scenario.

The customer who has become quite demanding with respect to cost, quality & variety
determines the market price. The current economic environment automatically brings
tremendous pressure on optimizing the project cost for survival. Monitoring and control fuel
consumption and skill up gradation of operative and project team is one of best solution.

Project cost can by optimized by enhancement of effectiveness of operation and maintenance,

productivity of manpower and equipment, technology, waste reduction and skill of employee.
All these factors have major impact in diesel consumption of equipments.

Principle of Operation of Diesel Engine:

Diesel engine (compression ignition engine) is the internal combustion engine, and used
widely as the power source of the construction equipment. In diesel engine, the air is entered
in the cylinder, and it is compressed adiabatically to a high temperature at the cylinder. When
the mists of the fuel are jetted into the high temperature cylinder, it combusts automatically
and push the piston back down, causing the crankshaft to rotate, the engine obtains the
output power, which power's vehicle's motion. It can get the higher efficiency by high
compression ratio and it can use light oil and heavy oil such as diesel as the fuel.

Diesel fuel contains more heat energy (BTUs or joules) and much less volatile. The diesel
engines design, including its high compression ratio, is intended to extract the maximum
amount of power from its fuel.

Formula to Estimate Maximum Engine Fuel Consumption

The fuel consumption rate for a piece of equipment depends on the engine size, load factor,
the condition of the equipment, operator's habit, environmental conditions, and the basic
design of equipment.

Fuel consumed is proportional to the power developed. Power developed is

approximately proportional to the cube of the engine revolution. Hence fuel consumed is
proportional to the cube of the engine revolution.

To determine the hourly fuel cost, the total fuel cost is divided by the productive time of the
equipment. If fuel consumption records are not available, the following formula can be used
to estimate liters of fuel used per machine hour,

LPH = (specific fuel consumption x KW) / Fuel Specific Weight * load factor
These formulas can be used, when the engine is making peak power, which usually is near
wide-open throttle. Fuel consumption will be decreased at cruising speeds. Also, engines with
electronically-managed fuel injection and direct injection will yield higher fuel efficiency.

Where,

LPH is the liters used per machine hour,

Specific Fuel consumption (at rated power): 0.2259 kg/KWH,

KW is the rated Kilowatt of equipment at governed engine rpm,

Fuel Specific Weight is specific gravity of fuel (weight of fuel in kg/liter): 0.85 kg/litre.

Load factor in percent (ratio of average load KW on engine to rated KW), and

Example:

Specific Fuel consumption (at rated power) is 225.9 g/KWh = K

Equipment Output is 129.6KW @ 2200 rpm = KW

According to the calculation = K*KW/KPL

= 0.226 *129.6 / 0.85

= 34.45 LPH (at full rated output of engine and full load)

If machine performs in 40 to 60% load as standard

= 34.45 * 40%

= 13.78 lts/ hr

Fuel consumption depends on following factors in construction equipment:

Engine size and engine type.

Drive type fitted with the engine

 Equipment design and aerodynamics (wind drag)

Quality of fuel

Load factor

Operating RPM of engine of the equipment,

Frequent stops, speed variations or otherwise poor operating habits,

Operator skill

Operating hours and working of engine.

Insufficient intake air and filtration of intake air of engine.

Calibration of engine fuel pump and injector

Compliance of recommended maintenance checklist

Gross vehicle weight

Ambient temperature, altitude, humidity,

Wind direction and velocity,

Terrain elevation changes etc,

Final gear ratio.

Wheel alignment and tire pressure.

Misadjusted or dragging brakes.

Fuel Saving Tips

When operating heavy machinery, certain practices can help in reduction of fuel consumption
and consequently reduction in operational costs.
 Inspect air filters regularly

Inspect air filters every 50 hours to ensure maximum operating performance. If air filter
becomes clogged with dirt, the engine cannot get the air it needs and does not operate
efficiently. Some machines have air flow indicators that indicate change or clean of air filter.

Grease fittings properly

Lubricate of machine according to manufacturers recommendations. By keeping your machine

properly lubricated, fuel efficiency is increased simply because the power needed to perform
operations is reduced. The more mobility the components have, the less work the hydraulic
system must perform.

Check tire pressure

Check tire air pressure before and after each use. If the tire pressure is low, fill the tires as
soon as possible. Low air pressure can reduce the efficiency of machine and lower fuel
efficiency.

Be alert for signs of a mechanical problem

When alert signs of a mechanical problem, such as excessive black smoke, urgent repair of is
better decision. Mechanical problems, such as a bad fuel injector, can significantly reduce fuel
efficiency. If your fuel injector is over fueling a cylinder, machine is wasting fuel.

Run engine at low RPM whenever possible

Begin by running at a low rpm during operation, then slowly raise the rpm until the engine
does not strain. This level will be the most efficient and effective rpm for the job. When a job
does not require maximum power, running the engine at a lower rpm can significantly reduce
fuel consumption.

Service and repair equipment regularly

Service of equipment (oil and filter change, tune up, exhaust system, brakes, spark plugs,
belts, hoses) as per manufacturer's guidelines is highly required. Maintain equipment in best
shape. If repairs of equipment are done immediately then also fuel consumption will reduce
and also prevent costly problems that could have been avoided in the future.
 Avoid aggressive acceleration

Try to avoid aggressive acceleration, and speeding. Driving this way will reduce fuel
consumption.

Avoid excessive idling

Dont leave a machine idling. When any machine is not in use, the engine should always be
off. Leaving a equipment running or idling can burn fuel without use.

Plan driving routes carefully

Obviously, the less driving required, the less fuel will be used. Factoring in travel aspects such
as congestion, high-traffic times, and busy roads can help reduce travel time. It is best to
avoid peak travel times such as rush hour, and find roads that are less frequented. However,
some vehicles, such as backhoes and cranes, may not legally be allowed to travel on certain
roads, so it can be wise to research the local laws before heading out to the job site.

Buy a Fuel-efficient Vehicle

First things first, during purchase new or used construction equipment, examine of vehicles
fuel-efficiency is required apart from other factor. Usually, vehicle with a manual transmission
turns out a better option as it provides the drivers with smart fuel economy.

Minimize drag and reduce excessive weight

Driving with the windows open, using roof or rear mounted racks and carrying heavy loads
increase vehicle drag. Additional weight decreases fuel efficiency. Clean equipment and
remove unnecessary heavy items (i. e. sandbags).

Proper selection of fuel

Use a lighter weight multigrade oil in the fall - A heavy oil decreases engine efficiency, which
can increase operating costs and emissions. Select the proper fuel for your vehicle as outlined
in the owner's manual. Avoid a higher-octane fuel; it is more harmful to the environment
because they require more crude oil to produce than lower octane fuels.

Operator experience, machine condition, job site conditions, all affect fuel
consumption rate.

Reduction in fuel consumption will help in reduction expensive vehicle repair and also helps
reduce emissions into the environment apart from reduction in construction cost.

Diesel consumption of different capacity engine at different load factor

Specific Fuel
Diesel Consumption Ltr / Hr
consumption Output at
rated KW Specific LF LF LF LF
(at rated at RPM Gravity
power ) @2200 of Fuel =25 % =50 % =75 % =100 %
0.2259 20 0.85 1.33 2.66 3.99 5.32
0.2259 40 0.85 2.66 5.32 7.97 10.63
0.2259 60 0.85 3.99 7.97 11.96 15.95
0.2259 80 0.85 5.32 10.63 15.95 21.26
0.2259 100 0.85 6.64 13.29 19.93 26.58
0.2259 120 0.85 7.97 15.95 23.92 31.89
0.2259 140 0.85 9.30 18.60 27.91 37.21
0.2259 160 0.85 10.63 21.26 31.89 42.52
0.2259 180 0.85 11.96 23.92 35.88 47.84
0.2259 200 0.85 13.29 26.58 39.86 53.15
0.2259 220 0.85 14.62 29.23 43.85 58.47
0.2259 240 0.85 15.95 31.89 47.84 63.78
0.2259 260 0.85 17.27 34.55 51.82 69.10
0.2259 280 0.85 18.60 37.21 55.81 74.41
0.2259 300 0.85 19.93 39.86 59.80 79.73
0.2259 320 0.85 21.26 42.52 63.78 85.04
0.2259 340 0.85 22.59 45.18 67.77 90.36
0.2259 360 0.85 23.92 47.84 71.76 95.68
0.2259 380 0.85 25.25 50.50 75.74 100.99
 0.2259 400 0.85 26.58 53.15 79.73 106.31
0.2259 420 0.85 27.91 55.81 83.72 111.62
0.2259 440 0.85 29.23 58.47 87.70 116.94
0.2259 460 0.85 30.56 61.13 91.69 122.25
0.2259 480 0.85 31.89 63.78 95.68 127.57
0.2259 500 0.85 33.22 66.44 99.66 132.88
0.2259 520 0.85 34.55 69.10 103.65 138.20
0.2259 540 0.85 35.88 71.76 107.63 143.51
0.2259 560 0.85 37.21 74.41 111.62 148.83
0.2259 580 0.85 38.54 77.07 115.61 154.14
0.2259 600 0.85 39.86 79.73 119.59 159.46

OUR MOTTO: