Establishing Soot Limits

for
Diesel Engines

Originally Prepared for the S.O.S Services 2002 Dealer Conference

by DS Nycz

Establishing Soot Limits

The Basics

Where does soot come from ?

How large are soot particles ?
Are soot particles abrasive ?
How does soot cause wear ?
What role do lubricants serve ?

Establishing soot limits

Originally Prepared for the S.O.S Services 2002 Dealer Conference

by DS Nycz

Soot Basics
Where does soot come from ?

Soot is the product of incomplete

combustion in diesel fueled engines.
Soot is formed by two processes in the
combustion chamber:

1. Low air/fuel ratio

2. Fuel impingement on the cylinder liner wall

Soot can also enter the oil through blowby,

caused by worn rings and cylinder liners.
Originally Prepared for the S.O.S Services 2002 Dealer Conference

by DS Nycz

Diesel Fuel Molecules

Where does
soot come
from ?

Air Molecules
Incomplete Combustion
Precursor Molecules
Nucleation
Soot nuclei

20 to 40 nm

Spherule
Soot
particle

Coalescent
Coagulation
Surface growth
Chain forming
Coagulation
Surface growth

Originally Prepared for the S.O.S Services 2002 Dealer Conference

by DS Nycz

Soot Basics
How soot enters the engine oil

Blowby gases passing through the

ring gaps
Blowby gasses passing by worn
piston rings and cylinder liners
Oil transfer along the honed
cylinder wall surface

Originally Prepared for the S.O.S Services 2002 Dealer Conference

by DS Nycz

Soot Basics
Where does soot come from ?

Causes of low air/fuel ratio

Plugged air filter

Boost leaks or Exhaust leaks ahead of turbo
Rubbing or Failed Turbocharger

Causes of fuel impingement on liners

Retarded Injection Timing

Incorrect, Worn, or Failed fuel injectors
Deposits on injector tips

Originally Prepared for the S.O.S Services 2002 Dealer Conference

by DS Nycz

Soot Basics
How large are soot particles ?

Recent research indicates a primary soot

particle size of 20 to 40 nm (.02 to .04 um)
Soot particles
have polarity
that causes
them to
agglomerate
and form
larger particles
Originally Prepared for the S.O.S Services 2002 Dealer Conference

by DS Nycz

Soot Basics
Are soot particles abrasive ?

Yes!
Recent studies have shown that primary
soot particles are equal to or harder than:
piston rings, cylinder liners, and hardened
valve train parts.
Surfaces, polished by soot, show wear
scars equal to and larger than the primary
soot particle size.
Originally Prepared for the S.O.S Services 2002 Dealer Conference

by DS Nycz

Soot Basics
How does soot cause wear ?

Soot related wear primarily occurs in areas

where oil films are thin.
Soot disrupts or removes the anti-wear film
on the surfaces.
The primary soot particle can scar the
surface or other types of wear can occur
when the anti-wear film is removed.
Originally Prepared for the S.O.S Services 2002 Dealer Conference

by DS Nycz

Soot Basics
What role do lubricants serve ?

Provide an adequate oil film thickness to

reduce abrasion and surface contact
Provide anti-wear additives that coat the
surfaces for additional protection
Disperse the soot to reduce agglomeration
of primary soot particles. This controls
viscosity increase and sludge formation.
Originally Prepared for the S.O.S Services 2002 Dealer Conference

by DS Nycz

Soot Basics
What role do lubricants serve ?

API
CF
CF-4
CG-4
CH-4

The API system has produced lubricants

that control the harmful effects of soot.
Test
T-7
T-8
T-8E
T-9
M-11

Soot Evaluation Tests

Soot-TGA
Parameter Measured
soot not evaluated
1.50%
Viscosity Increase
3.80%
Viscosity Increase
4.80%
Viscosity Increase
1.75%
Ring & Cyl Liner Wear
4.50% Valve Train Wear, Sludge, Filter Plugging

Originally Prepared for the S.O.S Services 2002 Dealer Conference

by DS Nycz

Soot Basics

Differences in lubricant formulations can

significantly change the soot and iron
readings from used oil samples!
950F 3126 Field Test

140

Cat CF 30

950F 3126 Field Test

40

Cat CG-4 15W-40

Cat CG-4 15W-40

35

120

30

100
Iron - PPM

Soot - % Allowable

Cat CF 30

80
60

25
20
15

40

10

20

0
0

50

100

150
200
Oil Hours

250

300

50

100

150

200

250

300

Oil Hours

Originally Prepared for the S.O.S Services 2002 Dealer Conference

by DS Nycz

Soot Basics
Differences in lubricant formulations can
significantly change the soot and iron
readings from used oil samples!

3406E Lab Cycle Test

CG-4 Soot

140

CH-4 Iron

80

CH-4 Soot

70

120

60

100
Iron - PPM

Soot - % Allowable

CG-4 Iron

3406E Lab Cycle Test

80
60
40

50
40
30
20

20

10

100

200

300
400
Oil Hours

500

600

700

100

200

300

400

500

600

700

Oil Hours

Originally Prepared for the S.O.S Services 2002 Dealer Conference

by DS Nycz

Establishing Soot Limits

Review of the Basics

Where does soot come from? Incomplete

combustion of diesel fuel
How large are soot particles? 20 to 40 nm
Are soot particles abrasive? Yes
How does soot cause wear? by disturbing
the anti-wear film and abrasion
What role do lubricants serve? oil film,
anti-wear additives, dispersants to control
agglomeration and viscosity
Originally Prepared for the S.O.S Services 2002 Dealer Conference

by DS Nycz

Establishing Soot Limits

Establishing soot limits

The variables in lubricant performance,

operating conditions, and engine design
restrict our ability to set accurate soot
limits.
Therefore, trend analysis must be used to
monitor differences in soot levels and wear.

Originally Prepared for the S.O.S Services 2002 Dealer Conference

by DS Nycz

Establishing Soot Limits

Soot limits and trend analysis
966G II example
966G II
After break-in data

966G II
After break-in data

200
180
160
140
120
100
80
60
40
20
0

120
100
Iron - PPM

Soot - % Allowable

80
60
40
20
0

100

200

300

400

Oil Hours

500

600

700

100

200

300

400

500

600

700

Oil Hours

Originally Prepared for the S.O.S Services 2002 Dealer Conference

by DS Nycz

Establishing Soot Limits

Soot limits and trend analysis

966G II example

The red machine was operating at altitude and

that accounted for the higher soot readings. The
higher level of soot increased iron wear.
Additional data will be needed to establish the
trend for the red machine.
Based on additional samples and trends, the
customer may be asked to reduce oil drains on
the red machine.

Originally Prepared for the S.O.S Services 2002 Dealer Conference

by DS Nycz

Establishing Soot Limits

Conclusions

Soot is abrasive and causes increased wear

in diesel engines.
Soot limits are difficult to determine because
of lubricant differences and engine design
differences.
Trend analysis is the best way to determine
normal soot levels for a particular machine.

Originally Prepared for the S.O.S Services 2002 Dealer Conference

by DS Nycz