Fluid Diagnostics

General Overview of FluiPak®

Products

© The Lubrizol Corporation 2006, all rights reserved

What is - FluiPak and FluiPak Lite for Diesel Engines?
• FluiPak • FluiPak Lite
– Control Box – Control/Sensor Box
• Permittivity
• Rotational Viscometer

– Sensor Box
• Permittivity
• Rotational Viscometer
– Regeneration Pump and Filter

– Reserve System
• Oil Leveling
• Oil in Fuel Reburn

© The Lubrizol Corporation 2006, all rights reserved

 Mining & Stationary Diesel FluiPak®

• Enhanced sensor technology from original

FluiPak®.
• Off-board database and trending tools developed
by Lubrizol.
• Applied in mining, stationary diesel, inland
marine and other 4-stroke diesel applications

CUSTOMER BENEFITS:
• Oil drain interval optimization
• Reduced waste oil disposal costs
• Engine component life extension
• Early failure detection
• Minimized planned or unplanned downtime
• Fills the blind spot between laboratory drain
analyses
• Optimized asset utilization

© The Lubrizol Corporation 2006, all rights reserved

FluiPak Flow Diagrams

© The Lubrizol Corporation 2006, all rights reserved

 FluiPak Lite Flow Diagram

1 qph (max 6 gpd)

© The Lubrizol Corporation 2006, all rights reserved

 FluiPak Flow Diagram

30 gallon

10 gph

4 gph
2 Micron

1 qph (max 6 gpd)

© The Lubrizol Corporation 2006, all rights reserved
 Reserve System Flow Diagram
Mining & Stationary Diesel FluiPak®

FluiPak System Oil Level/Regeneration in Operation

controls
ENGINE FUEL RETURN TO TANK
Metering Pump
based
on engine oil BLENDED OIL/FUEL
quality FUEL TO BLENDING
Sensor AIR RELIEF VALVE
measurements.
OIL/AIR SEPARATOR
RETURN TO
AMCD ENGINE MB571

M
B

R2000 FUEL
ENGINE TANK
1

OIL LEVEL

METERED OIL
OIL/AIR REMOVAL FILTER

SUPPLY TANK

© The Lubrizol Corporation 2006, all rights reserved

 FluiPak® Product Concept
• Continuous measurement of engine oil quality through proprietary sensor technologies
• Oil Contamination Detection
– Water, Glycol, Soot, Fuel Dilution
• Pre-set oil condemning thresholds
– Established with end user on application basis
• Continuous oil leveling system ensuring proper level in oil pan irrespective of asset position
• Oil regeneration activated as oil quality thresholds are breached

Typical - 250 Hour Oil Change Interval Oil Quality Controlled At Set-Point
2.5

2.45

2.4

2.35 •Extends Oil Drain Interval

•Reduces need for customer top-offs.
•Can identify incipient failure events such as
2.3
fuel or
coolant contamination in crankcase lube.
2.25
06/10 06/17 06/24 07/01 07/08 07/15

RESULT: Continuous oil quality monitoring and changes allowing asset

uptime + early detection of failures
© The Lubrizol Corporation 2006, all rights reserved
 Haul Truck Soot Reduction
70.00
Truck
Truck not Equipped with FluiPak Equipped with Truck
FluiPak®, Equipped with
60.00
Reburn not FluiPak®,
active Reburn active
soot (as measured by Oil Analysis Inc)

50.00

40.00
VISCOSITY
SOOT
30.00

20.00

10.00

0.00
9/15/2003

11/15/2003

1/15/2004

3/15/2004

5/15/2004

7/15/2004

9/15/2004

11/15/2004

1/15/2005

3/15/2005

5/15/2005

7/15/2005

9/15/2005

11/15/2005

1/15/2006

3/15/2006

5/15/2006

7/15/2006
date
© The Lubrizol Corporation 2006, all rights reserved
Data above is drain oil analysis
 Haul Truck Soot Reduction and Fuel Dilution Event
(see next slide for comparative sensor data)
30.00
T ruck
T ruck
Equipped with
T ruck not Equipped with FluiPak Equipped with
FluiPak® ,
FluiPak®,
R eburn not
25.00 Reburn active
active
soot (as measured by Oil Analysis Inc)

20.00

VISCO SITY
15.00
SO O T

10.00 potential fuel leak

5.00

0.00
7/1/2003

9/1/2003

11/1/2003

1/1/2004

3/1/2004

5/1/2004

7/1/2004

9/1/2004

11/1/2004

1/1/2005

3/1/2005

5/1/2005

7/1/2005

9/1/2005

11/1/2005

1/1/2006

3/1/2006

5/1/2006

7/1/2006
date
© The Lubrizol Corporation 2006, all rights reserved
Data above is drain oil analysis
 Initial Fuel Dilution Detected

© The Lubrizol Corporation 2006, all rights reserved

Data above is on-board sensor oil analysis
 Supply Voltage + 5 VDC
Operating Temperature 20°-110° C
FluiPak® Diagnostics Range
Performance:
Minimum Permittivity 2.16 є
Maximum Permittivity 3.15 є
Signal Tolerance ±2.0% of full
• Permittivity Sensor scale
– Designed to measure properties of engine oil which correlate to oil
condition via Lubrizol proprietary algorithms
Permittivity is a
Waterleak Detection
physical quantity
3.4 that describes how
an electric field
3.2 affects and is
Engine shut dow n affected by a
3 dielectric medium,
and is determined
2.8 by the ability of a
Oil Level

material to polarize
2.6
in response to the
Warning w ould have been field, and thereby
initiated here in just over 24hrs reduce the field
2.4
Water leak began inside the material.
Thus, permittivity
2.2
relates to a
material's ability to
2
transmit (or
Tim e (2.5 days total tim e fram e)
"permit") an electric
permittivity
field.
© The Lubrizol Corporation 2006, all rights reserved
 Supply Voltage 12-36 VDC
Oil Pressure 40 PSI to 100 PSI

FluiPak® Diagnostics Temperature Range 65°-110° C

Performance:
Minimum Viscosity 6.0 cP
Maximum Viscosity 20.0 cP
• Rotational Viscometer Signal Tolerance ±5.0% of full scale

– Measures viscosity of lubricant; correlates to lab kinematic viscosity

tests
– Used to detect fuel leaks or soot thickening.

Fuel Leak Detection

Increasing negative slope indicates

worsening fuel leak over time.

© The Lubrizol Corporation 2006, all rights reserved

 Mining & Stationary Diesel FluiPak®
Level Control & Regeneration
• Continuous adjustment of engine oil level
• Condition based regeneration of engine oil
• Automatic, accurate, rapid filling of engine oil reservoir
• Extended oil drain intervals
• Extended engine component life

Operating Voltage 24 VDC

Max. In-Rush Current 40 Amps

Reservoir Tank Capacity 10-80 Gallons

Performance:

Oil Level Control Continuously maintains oil at set point

Regeneration Rate 2 liters/hr max.

© The Lubrizol Corporation 2006, all rights reserved

Installation Photographs

© The Lubrizol Corporation 2006, all rights reserved

Reserve System Installation

© The Lubrizol Corporation 2006, all rights reserved

Sensor Box Installation

© The Lubrizol Corporation 2006, all rights reserved

Control Box Installation

© The Lubrizol Corporation 2006, all rights reserved

FluiPak Lite Installation

CAT D11R Dozer

© The Lubrizol Corporation 2006, all rights reserved
 FluiPak Mining Value
Proposition

The following analysis was conducted

by an independent
party trialing the
Lubrizol FluiPak ® Systems
at a mine site in North America.
The value stated in the following tables
reflects the views
and analysis of this individual and his
firm.
© The Lubrizol Corporation 2006, all rights reserved
 Engine hours
Life extension factor 1.25
Engine Component Life Extension
Engine hours 20,000 -25% overhaul extension
Rebuild costs $210,000.00 -Assumes 20K/hr overhaul interval
Costs/hour $10.50
New hours 25000
Cost/hour $8.40
Savings/hour $2.10
Savings per truck $12,600
overhaul/annum
Oil Drain Labor Changes
-6000 hr/annual usage
Labor Savings on OCI Assume 250 hr OCI
Labor/change 1 -FluiPak® extends to 500 hr OCI
labor costs/hour $30.00 -Eliminates 12 oil changes/annum
30
total costs $30.00
Total labor savings per truck $360.00
© The Lubrizol Corporation 2006, all rights reserved
Injector Savings
Injector Life Improvement 1.5
Result of Regen System on Injectors
factor
-Injector life extension through oil
Cost per injector set $12,000 regeneration
Current life 16 mos
New Life 24 mos -Assume 50% increase in injector life
Injector savings $3,000
-Typical 16 month life of injectors
Current years to change out 1.33 increases to 24 month life
New years to change out 2
Per truck savings per annum $3,000

Fuel Savings Fuel Savings through Regen

Diesel Cost $1.50 -6000 operating hours per year

Engine Operating hrs/yr 6000 -Regeneration occurs 3,960 hrs

% Time in Regen 66 (66%) of operation
Hrs in regen per year 3960
- .26 gallons/hour while in
Regen rate gal/hr 0.26
regeneration
Total oil consumed gal/yr 1,030
Fuel value of oil 0.5 -1,030 gallons/yr. burned as fuel
Fuel Savings per/yr $772.00
© The Lubrizol Corporation 2006, all rights reserved
Lubricant Disposal
Current Drain 250
New Drain Equivalent 500
Lubricant Disposal Savings
Gals 57
-Assume $.50/gallon disposal
Hours per year 6000
cost
Current oil drains/yr 24 -Savings do not reflect labor or
Gals/year 1368 storage associated with
Cost/gal $0.50 disposal
Cost/year $684.00
New Drain/year 12
Cost/yr $462.00
gal/year 684
Disposal Savings Per Truck $222.00

Filter savings
Filters per engine 4
Filter Costs $160.
Per year Current $3,840
New $1,920
Filter savings $1,920
© The Lubrizol Corporation 2006, all rights reserved
 Vehicle Uptime Level & Regen
Productivity value of Equipment $250
$/hr
Oil changes saved 12

Hrs/oil change 1 Uptime/Availability

Truck down cost avoided $/yr $3,000
-Assume 250 hr OCI
to 500 hr OCI
-Assume $250 per
hour availability value
Vehicle Uptime Early Warning
-Assume engine
Diagnostic System
operates 6000/hrs/yr
Productivity value of Equipment $250 ~16.5 hr/day
$/hr 1% avoided downtime
Unscheduled Maintenance 1% = 60hrs equates 3.6 days
Avoided
Parts & Labor TBD

Truck down cost avoided $/yr $15,000

© The Lubrizol Corporation 2006, all rights reserved

 Materials, Labor and Uptime per Year

Category Value
Engine Component Life Extension $12,600

Oil Drain Labor Change $360

Injector Life Extension $3,000

Fuel Savings $772

Lube Disposal $222

Filter Savings $1,920

Vehicle Uptime $18,000

Total >$36,800/yr

Note: $15,000 (not including parts & labor) saved from diagnostics system alone

© The Lubrizol Corporation 2006, all rights reserved

 Thank You
Ron O. Dunfee
Global Sales Manager
(440) 347-6116
rod@lubrizol.com

© The Lubrizol Corporation 2006, all rights reserved