Demonstration of 2 nd Generation Vegetable Oil Fuels in Advanced Engines Workpackage 05 Engine demonstration Deliverable N 5.7: Fleet monitoring Report - Waldland Publishable summary Version: 01 Oberwaltenreith, 24 th of October 2011 prepared by: WALDLAND Hannes Blauensteiner (WALDLAND), Christine Schübl (WALDLAND) Oberwaltenreith 10 A-3533 Friedersbach Tel.: +43 2826-7443 Fax.: +43 2826-7443-500 Email: hannes.blauensteiner@waldland.at christine.schuebl@waldland.at Partner website: www.waldland.at Project website : www.2ndvegoil.eu
This publication has been produced with financial support of the European Commission in the frame of the FP7 Seventh Framework Programme under the grant agreement N TREN/FP7EN/219004/ 2ndVegOil. The sole responsibility for the content of this publication lies with the authors. It does not necessarily reflect the opinion of the European Communities. The European Commission is not responsible for any use that may be made of the information contained therein. 2
Table of content 1 Demonstration Fleet Waldland, Austria... 4 1.1 Overview... 4 1.2 ID 03 Waldland... 5 1.2.1 Application field and operating hours... 5 1.2.2 Overview plant oil fuel amount... 6 1.2.3 Services... 6 1.2.4 Re-Conversion... 8 1.2.5 Operators feedback... 8 1.3 ID 04 Mertelseder... 9 1.3.1 Application field and operating hours... 9 1.3.2 Overview plant oil fuel amount... 9 1.3.3 Services... 9 1.3.4 Re-Conversion...10 1.3.5 Operators feedback...10 1.4 ID 05 MR Zwettl-Weitra...11 1.4.1 Application field and operating hours...11 1.4.2 Overview plant oil fuel amount...12 1.4.3 Services...12 1.4.4 Re-Conversion...16 1.4.5 Operators feedback...17 1.5 ID 06 Oberleitner...18 1.5.1 Application field and operating hours...18 1.5.2 Overview plant oil fuel amount...18 1.5.3 Services...19 1.5.4 Re-Conversion...21 1.5.5 Operators feedback...22 1.6 ID 07 Rasner...23 1.6.1 Application field and operating hours...23 1.6.2 Overview plant oil fuel amount...24 1.6.3 Services...24 1.6.4 Re-Conversion...25 1.6.5 Operators feedback...25 2 Comment...25 3
1 Demonstration Fleet Waldland, Austria 1.1 Overview Tractor Tractor ID ID-4 Waldland L07530N604252 ID-5 Waldland L07430R604221 ID-6 Waldland L06830R604694 ID-7 Waldland L07430R604472 ID-3 JDWM L07530N613561 Operator Workshop Fuel Mr. Josef MERTELSEDER Maschinenring Zwettl-Weitra KG Mr. Markus ARTNER Mr. Johann OBERLEITNER Mr. Johann RASNER Waldland Mr. Philipp BRANDSTETTER Innviertler Lagerhausgenossenschaft egen. Zentrale Geinberg Mr. Wolfgang SCHREMS Moosham 35 A-4943 Geinberg Tel. +43/7723/42208-0 www.lagerhaus-innviertel.at Raiffeisen Lagerhaus Zwettl (Truck Workshop) Mr. Hannes BAUER Galgenbergstr. 22 A-3910 Zwettl Tel. +43/2822/506-571 http://www.lagerhauszwettl.at/ RLH Wieselburg Mr. Karl HUBER Beethovenstr. 3 A-3250 Wieselburg Tel. +43/7416/52332-29 http://www.lagerhausmostviertelmitte.at/ Lagerhaus Technik- Center GmbH & Co KG Mr. Norbert LECHNER Johann Pamer Str. 1 A-2100 Korneuburg Tel. 343/2262/71260-0 www.lagerhaustc.at Raiffeisen Lagerhaus Zwettl (Truck Workshop) Mr. Hannes BAUER Galgenbergstr. 22 A-3910 Zwettl Tel. +43/2822/506-571 http://www.lagerhauszwettl.at/ Rape seed Rape seed Camelina Rape seed Rape seed Rape seed Sunflower Re- Conversion for Diesel No No Yes Yes Back to John Deere, Mannheim Interval engine oil change and sampling The engine oil of the PPO tractors was changed in interval of 250 operating hours, and a sample pulled and sent for analyzing to Lubrizol. The ID-05 (MR Zwettl-Weitra) was also operated with camelina oil, wherefore additional samples were pulled each 125 operating hours. 4
1.2 ID 03 Waldland Operator: Waldland Tractor ID: L07530N613561 Type: 7530 Tractor: ID-03 Plant oil fuel: Rape seed, Sunflower Additiv: Protect 100 Motor oil: ACEA E 7 Testing period: 03.05.2010 30.06.2011 Picture 1: Operators ID-03 Waldland 1.2.1 Application field and operating hours Tractor was taken over by Waldland from John Deere (Mannheim), on the 3 rd of May 2010 with 668.7 rape seed oil operating hours. The last engine oil change was done at 615 operating hours. Waldland used the tractor primarily for cultivation and transport, on the end of testing period 1,388.1 operating hours (30.06.2011) done. 5
1.2.2 Overview plant oil fuel amount Table 1: Overview plant oil fuel amount Date Plant oil Amount [Litre] Rape seed (JD Mannheim) 31.05.2010 Sunflower 2,000 07.07.2010 Sunflower 1,000 17.08.2010 Rape seed 2,000 08.09.2010 Sunflower 1,000 12.04.2011 Sunflower 2,000 06.07.2011 Sunflower 4,000 Amount of plant oil: 12,000 1.2.3 Services 1.2.3.1 Engine oil services Table 2: Overview engine oil services Sampling date Oil age [h] Operating hours Plant oil fuel Dispatch to Lubrizol, date 08.06.2010 108.5 723.5 Rape seed 29.06.2010 23.08.2010 149.5 873 Sunflower 26.08.2010 12.10.2010 211 1,018 Sunflower 19.10.2010 19.10.2010 233 1,040 Sunflower 19.10.2010 06.06.2011 310.2 1,352.2 Sunflower 08.07.2011 6
1.2.3.2 Power test reports 1.2.3.2.1 Power test - 11.05.2010 (Rape seed) 1.2.3.2.2 Power test, SCRi system In John Deere factory Mannheim where done additional power tests, one before the installation of the SCRi exhaust gas after treatment system and one power test after the conversion. 7
1.2.3.3 Activities Table 3: Overview activities Activities Operating hours Date Activity Person in charge 771.0 4.-26.07.2010 SCRI Installation JD Mannheim 800.4 25.08.2010 Exchange Control Unit JD Mannheim 959.7 18.09.2010 Rep. Fa. EMITEC Ad blue system Waldland 1,045.2 15.10.2010 Rep. Fa. EMITEC Ad blue system Waldland Rep. exhaust gas secondary treatment 1,089.0 29.10.2010 1,172.0 22.02.-28.03.2011 system Conversion of a new SCRI System and power test November 2011 planned Engine disassembly and power test Waldland JD Mannheim JD Mannheim 1.2.4 Re-Conversion Tractor was resent to John Deere factory Mannheim. 1.2.5 Operators feedback Waldland was very satisfied with the performance of the PPO tractor, except the mechanical problems with the SCRi after treatment system, the tractor worked well. 8
1.3 ID 04 Mertelseder Operator: Johann MERTELSEDER Tractor ID: L07530N604252 Type: 7530 Tractor: ID-04 Plant oil fuel: Rape seed Additiv: Lubrizol Motor oil: ACEA E 9 Testing period: 01.04.2009 30.06.2011 1.3.1 Application field and operating hours Tractor was primarily used for ploughing, cultivation and transport in agriculture. On the end of testing period 665 operating hours where done (30.06.2011). 1.3.2 Overview plant oil fuel amount Table 4: Overview plant oil fuel amount Date Plant oil Amount [Litre] 17.03.2009 Rape seed 4,030 13.10.2009 Rape seed 3,066 30.08.2010 Rape seed 3,975 17.05.2011 Rape seed 4,000 Amount of plant oil: 15,071 1.3.3 Services 1.3.3.1 Engine oil services Table 5: Overview engine oil services Sampling date Oil age [h] Operating Dispatch to Plant oil fuel hours Lubrizol, date 15.07.2010 251 358 Rape seed 08.07.2011 29.03.2011 250 608 Rape seed 08.07.2011 9
1.3.3.2 Power test reports 1.3.3.2.1 Power test 27.05.2011 Because of results of power test change of injectors decided and realized on 20.06.2011. 1.3.3.3 Activities Table 6: Overview activities Activity Operating hours Date Activity Person in charge 660 20.06.2011 Exchange of injectors RLH Geinberg 20.06.2011 Usage of a new additive Protect 100 1.3.4 Re-Conversion The tractor will not be re-converted and is taken over with the new technology by operator. 1.3.5 Operators feedback The operator was very satisfied with the tractor in test period, despite problems with injectors caused by additive, he decided for further operation with plant oil. 10
1.4 ID 05 MR Zwettl-Weitra Operator: MR Zwettl-Weitra (pre-operator ÖKO Verein) Tractor ID: L07430R604221 Type: 7430 Tractor: ID-05 Plant oil fuel: Rape seed, Camelina Additiv: Protect 100 Motor oil: ACEA E 9 Testing period sum: 01.03.2009 30.06.2011 thereof tested by: ÖKO Verein: 17.03.2009 05.11.2009 MR Zwettl-Weitra: 01.03.2010 30.06.2011 Picture 2: ID-05 in operation by MR Zwettl-Weitra (Mr. Artner) 1.4.1 Application field and operating hours The tractor was first operated by ÖKO Verein later by MR Zwettl-Weitra. ÖKO Verein and MR Zwettl-Weitra used the tractor for a number of agricultural activities (e.g. ploughing, combined growing, transportation, mulching). On the end of testing period 1,706 operating hours (30.06.2011) where done. Of that 577.1 operating hours where done by ÖKO Verein (05.11.2009) and 1,128.9 hours by MR Zwettl- Weitra (30.06.2011). 11
1.4.2 Overview plant oil fuel amount Table 7: Overview plant oil fuel amount Date Plant oil Operator Amount [Litre] 18.03.2009 Rape seed ÖKOVerein 2,800 21.08.2009 Rape seed ÖKOVerein 4,000 19.10.2009 Rape seed ÖKOVerein 2,000 18.01.2010 Rape seed ÖKOVerein 1,350 03.03.2010 Rape seed MR Zwettl-Weitra 1,993 07.04.2010 Rape seed MR Zwettl-Weitra 1,990 31.05.2010 Camelina MR Zwettl-Weitra 1,000 27.07.2010 Camelina MR Zwettl-Weitra 4,000 27.09.2010 Camelina MR Zwettl-Weitra 1,000 06.10.2010 Camelina MR Zwettl-Weitra 2,870 14.03.2011 Camelina MR Zwettl-Weitra 3,045 21.03.2011 Camelina MR Zwettl-Weitra 2,060 03.06.2011 Camelina MR Zwettl-Weitra 1,730 26.07.2011 Rape seed MR Zwettl-Weitra 1,000 Amount of plant oil: 30,838 1.4.3 Services 1.4.3.1 Engine oil services Table 8: Overview engine oil services Sampling date Oil age [h] Operating Dispatch to Plant oil fuel hours Lubrizol, date 30.04.2010 205 785 Rape seed 05.07.2010 12.07.2010 124 909 Camelina 22.07.2010 16.08.2010 200 975 Camelina 19.10.2010 01.09.2010 122 1,097 Camelina 19.10.2010 24.09.2010 270 1,245 Camelina 19.10.2010 18.10.2010 130 1,375 Camelina 19.10.2010 25.03.2011 251 1,496 Camelina 08.07.2011 18.05.2011 144 1,640 Camelina 08.07.2011 12
1.4.3.2 Power test reports 1.4.3.2.1 Power test report 21.05.2010 (Rape seed) 13
1.4.3.2.2 Power test report 21.07.2010 (Camelina, reference values) 14
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1.4.3.2.3 Power test report 04.07.2011 (Camelina, before engine inspection) The power test was done before engine inspection (disassembling) and injectors changed. 1.4.3.3 Activities Engine disassembly for 2ndVegOil inspection by Raiffeisen Lagerhaus Zwettl (Austria) on 5.07.2011. 1.4.4 Re-Conversion The tractor will not be re-converted and is taken over with the new technology by operator. 16
1.4.5 Operators feedback The responsible operator Mr. Artner of MR Zwettl-Weitra noticed that the performance in application with the camelina oil was in his opinion lower than the measurements of the power test (21.07.2010). In comparison of rape seed and camelina oil in practice were very low performance differences remarkable. Mr. Artner is generally satisfied with the plant oil tractor and he will take over the new engine technology for PPO. 17
1.5 ID 06 Oberleitner Operator: Johann OBERLEITNER Tractor ID: L06830R604694 Type: 6830 Tractor: ID-06 Plant oil fuel: Rape seed Additiv: Lubrizol Motor oil: ACEA E 7 Testing period: 01.06.2009 30.06.2011 1.5.1 Application field and operating hours Tractor was used primarily for pressing bales and for winter service (e.g. snow vacate). For winter service diesel was blended into rape seed oil. On the end of testing period 2,724 operating hours where done (30.06.2011). 1.5.2 Overview plant oil fuel amount Table 9: Overview plant oil fuel amount Date Plant oil Amount [Litre] 09.03.2009 Rape seed 4,085 26.06.2009 Rape seed 3,965 25.08.2009 Rape seed 3,942 07.10.2009 Rape seed 1,993 12.01.2010 Rape seed 2,037 02.04.2010 Rape seed 4,085 29.06.2010 Rape seed 4,019 01.09.2010 Rape seed 4,000 23.03.2011 Rape seed 4,000 05.07.2011 Rape seed 2,000 Amount of plant oil: 34,126 18
1.5.3 Services 1.5.3.1 Engine oil services Table 10: Overview engine oil services Operating Dispatch to Sampling date Oil age [h] Plant oil fuel hours Lubrizol, date 02.05.2011 250 2,467 Rape seed 08.07.2011 1.5.3.2 Power test reports 1.5.3.2.1 Power test report 01.04.2010 The power test was done in cause of performance problems with the PPO tractor. The performance decreased continuous, as the engine run poorly by cold start. 19
1.5.3.2.2 Power test report 16.06.2010 A second power test was done because of steady low performance, ongoing injectors were changed. 20
1.5.3.2.3 Power test report 23.06.2011 Test results are given before the second injector change. 1.5.3.3 Activities Table 11: Overview activities Activities Operating hours Date Activity Person in charge 1.377 01.04.2010 Power Test RLH Wieselburg 1.625 16.06.2010 Power Test and first change of injectors RLH Wieselburg 2.690 23.06.2011 Power Test and second change of injectors RLH Wieselburg 5.07.2011 Transfer to Protect 100 1.5.4 Re-Conversion The tractor will be re-converted. 21
1.5.5 Operators feedback Mr. Oberleitner used the plant oil tractor also for winter services and was satisfied, excepted need of improvement of the lower performance compared with diesel operation. 22
1.6 ID 07 Rasner Operator: Johann RASNER Tractor ID: L07430R604472 Type: 7430 Tractor: ID-07 Plant oil fuel: Rape seed Additiv: Protect 100 Motor oil: ACEA E 7 Testing period: 23.03.2009 30.06.2011 Picture 3: Mr. Rasner refilling the tractor with rape seed oil 1.6.1 Application field and operating hours Tractor was used for variable agricultural application, but most time for more heavy machine work, like combined seeding or ploughing. On the end of testing period 3,270 operating hours where done (30.06.2011). 23
1.6.2 Overview plant oil fuel amount Table 12: Overview plant oil fuel amount Date Plant oil Amount [Litre] 10.03.2009 Rape seed 3,943 27.04.2009 Rape seed 4,008 28.05.2009 Rape seed 4,107 12.08.2009 Rape seed 3,975 08.10.2009 Rape seed 2,957 12.11.2009 Rape seed 2,032 01.03.2010 Rape seed 4,008 26.04.2010 Rape seed 4,030 02.07.2010 Rape seed 4,040 28.09.2010 Rape seed 2,015 08.10.2010 Rape seed 2,000 05.11.2010 Rape seed 2,015 23.03.2011 Rape seed 4,000 17.05.2011 Rape seed 4,000 26.07.2011 Rape seed 1,000 Amount of plant oil: 48,130 1.6.3 Services 1.6.3.1 Engine oil services Table 13: Overview engine oil services Sampling date Oil age [h] Operating Dispatch to Plant oil fuel hours Lubrizol, date 27.04.2010 215 1,710 Rape seed 29.06.2010 22.06.2010 285 1,995 Rape seed 29.06.2010 Sampling forgotten Rape seed by service - 2,249.5 - point 15.10.2010 210.5 2,460 Rape seed 09.02.2011 01.12.2010 290 2,750 Rape seed 09.02.2011 24
1.6.3.2 Power test reports 1.6.3.2.1 Power test report 5.07.2011 Table 14: Results power test 5.07.2011, RLH Wr. Neustadt PTO speed PS 1.000 158 950 163 900 163 850 150 800 140 750 140 700 133 1.6.3.2.2 Power test report 6.07.2011 On 06.07.2011 was a final PTO metering done by the workshop Raiffeisen Lagerhaus Wr. Neustadt. There are only one power test done, because of the proper functioning of the tractor. The results were directly sent to John Deere. 1.6.3.3 Activities Engine disassembly and endoscopy for 2ndVegOil inspection by workshop Raiffeisen Lagerhaus Wr. Neustadt on 06.07.2011. 1.6.4 Re-Conversion The tractor will be re-converted, although a high satisfactory with the technology and very positive feedback of operator. 1.6.5 Operators feedback The operator was very satisfied with the plant oil tractor. The filters change was more times required, especially in autumn/winter, but that s no deficit. Because of the lack of technology risk and further service of John Deere Mannheim couldn t been guaranteed decided the operator for re-conversion of tractor. 2 Comment Two tractors showed problems with decreasing power due to injector coking. The most likely reason is that the keep clean additive dosage rate in that case did not fit its formulation. With the JD keep clean additive (Protect 100), no such problems occurred. 25