This report details the initial activities to evaluate the performance of the oil bypass filter technology being tested by the Idaho National Engineering and Environmental Laboratory (INEEL) for the U.S. Department of Energy's FreedomCAR & Vehicle Technologies Program. Eight full-size, four-cycle diesel-engine buses used to transport INEEL employees on various routes have been equipped with oil bypass systems from the puraDYN Corporation. Each bus averages about 60,000 miles a year. The evaluation includes an oil analysis regime to monitor the presence of necessary additives in the oil and to detect undesirable contaminants. Very preliminary economic analysis suggests that the oil bypass system can reduce life-cycle costs. As the evaluation continues and oil avoidance costs are quantified, it is estimated that the bypass system economics may prove increasingly favorable, given the anticipated savings in operational costs and in reduced use of oil and waste oil avoidance.iii CONTENTS
This Oil Bypass Filter Technology Evaluation quarterly report (January-March 2004) details the ongoing fleet evaluation of an oil bypass filter technology by the Idaho National Engineering and Environmental Laboratory (INEEL) for the U.S. Department of Energy's FreedomCAR & Vehicle Technologies Program. Eight four-cycle diesel-engine buses used to transport INEEL employees on various routes have been equipped with oil bypass filter systems from the puraDYN Corporation. The bypass filters are reported to have engine oil filtering capability of <1 micron and a built-in additive package to facilitate extended oil-drain intervals. This quarter, the heavy-duty buses traveled 88,747 miles, and as of the end of March 2004, the eight buses have accumulated 412,838 total test miles without requiring an oil change. This represents an avoidance of 34 oil changes, which equates to 1,199 quarts (300 gallons) of new oil not consumed and, furthermore, 1,199 quarts of waste oil not generated. Also this quarter, the light-duty Tahoe test vehicles traveled 62,124 miles, and to date, the six Tahoes have accumulated 81,517 total test miles. This represents an avoidance of 27 oil changes, which equates to 135 quarts (34 gallons) of new oil not consumed and, consequently, 135 quarts of waste oil not generated. However, the quality of the oil in the Tahoes has deteriorated to the point of requiring replacement (Low Total Base Number). The low TBN of the used Tahoe oils is likely due more to the quality of recycled oil initially used in the test than the bypass filters; the recycled oil in the six Tahoes will be replaced with Castrol oil and the testing will restart. To validate the extended oil-drain intervals, an oil-analysis regime is used to evaluate the fitness of the oil for continued service by monitoring the presence of necessary additives, undesirable contaminants, and engine-wear metals. A more in-depth oil-analysis regimen has been added that focuses on the analysis of particulates, to evaluate the effectiveness of the filters and to ensure that the engines are not experiencing undetected wear due to the extended oil drains intervals.
This Oil Bypass Filter Technology Evaluation final report documents the feasibility of using oil bypass filters on 17 vehicles in the Idaho National Laboratory (INL) fleet during a 3-year test period. Almost 1.3 million test miles were accumulated, with eleven 4-cycle diesel engine buses accumulating 982,548 test miles and six gasoline-engine Chevrolet Tahoes accumulating 303,172 test miles. Two hundred and forty oil samples, taken at each 12,000-mile bus servicing event and at 3,000 miles for the Tahoes, documented the condition of the engine oils for continued service. Twenty-eight variables were normally tested, including the presence of desired additives and undesired wear metals such as iron and chrome, as well as soot, water, glycol, and fuel. Depending on the assumptions employed, the INL found that oil bypass filter systems for diesel engine buses have a positive payback between 72,000 and 144,000 miles. For the Tahoes, the positive payback was between 66,000 and 69,000 miles.
Executive SummaryDuring fiscal year 2006, the Idaho National Laboratory (INL) performed the several tests and other work to finalize the design for closure of Mobile Melt-Dilute (MMD) canisters.Several minor changes were made to the shield plug design. The closure groove weld between the top of the canister and the top plate of the shielding plug was reduced from 0.5-in deep to 0.375-in. The chamfer groove diameter was increased for the plug weld. A lifting pintle replaced a lifting lug. A groove for a plug cap was machined into the top plate and a cap was designed to weld over the plug to seal the canister. Drawings were revised to reflect these changes.A quick disconnect valve had been designed to provide the capability to maintain the canister at deep vacuum, once the fuel is dried. Testing performed during 2005 yielded unacceptable results, so the project investigated the problem and re-tested with improved results. Upon analysis of the test, it was discovered that the test had been compromised because the fittings had been welded incorrectly.To correct the test, quick disconnect test was divided into two parts: Threaded Seal Test and the Heated Vacuum Test. The Threaded Seal Test duplicated the failed 2005 test. When tested, the internal seals of two sets of fittings were heated to 500° C, and held a 200 millitorr vacuum. Over two days of testing, two fittings held vacuum and one failed. The failed fitting may have been attributed to a handling error by the testers. When the decision is made to proceed with the MMD system, the project should procure and test production-run valves to ensure performance of these precision devices.An alterative to using the quick disconnect fitting was investigated. Three sizes of stainless steel tubing, 0.25-in, 0.375-in, and 0.5-in, all with 0.035-in wall thickness, were successfully pinch or seal weld using commercially available resistance welding equipment from Centerline Special Machinery Division in Windsor, Ontario, Canada. Also preliminary studies conducted at University of Windsor showed that stainless steel tubing pinch welds can be real-time inspected with ultrasonic inspection methods.Three additional documents are included with this report: a closure welding machine specification, a canister and assembly component specification and an Idaho National Laboratory Engineering Design File report on the welding code justification of the welding changes made on the shield plug.
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