Recently completed testing by an independent testing facility
with support from a leading bearing manufacturer has confirmed
what experts at SAE and McDonnell Douglas Transportation Dept.
have been saying for years. Most of the mechanical wear in an
engine occurs during engine start-up. Oil pressure is non-existent
during the critical high stress, high torque, first seconds of
start-up.
Two identical engines were tested; one with a ESP-luber
system, the other without. The ESP-luber equipped engine
showed less scuffing and up to 53% of the bearing wear was
eliminated in the engine equipped with the ESP-luber system.
REDUCES ENGINE WEAR
Mechanical Wear - The removal of metal that occurs
when engine parts are temporarilly devoid of lubrication and
metal meets metal.
Studies by SAE and McDonnell Douglas indicate that the majority
of the wear occurs at start-up.
(Fig.1)
Bearing in motion (at left) shows oil separating surface. The
parts virtually ride on a thin film of oil. Bearing with engine
shut off (right) shows metal to metal contact.
(Fig. 2)
Polished bearing surface magnified approximately 10,000 times.
In Fig. 2A, oil pressure forces the bearing apart, metal to
metal contact cannot take place. However, when an engine is shut
off, the film of oil collapses and metal to metal contact occurs
(Fig. 2B). When you next start the engine, you tear off the
peaks of metal, which are then carried away in the oil (Fig.
2C). This is how a part is worn out. The ESP-luber system
eliminates the metal to metal wear by automatically pressurizing
the entire engine before it is started (Fig. 2D).
Illustrations courtesy of McDonnell Douglas
Transportation Dept. and Bob Sikorski in "Drive it
Forever", McGraw-Hill Publishing
Abrasive Wear - Contamination of the oil causes
abrasion which results in scratching the bearing surfaces.
The contamination comes from three main sources: combustion
by-products, atmospheric dust, and mechanical wear debris
(graphically depicted below).
Engine under normal operating condition.
Mechanical wear debris is virtually eliminated in
engines equipped with a ESP-luber system.
The best way to prevent abrasive wear is to eliminate the
abrasives that cause the wear. ESP-luber eliminates the
hard metal oxides produced by mechanical wear, which reduces oil
contamination and abrasive wear.
EXTENDS
TURBO LIFE
Oil is the life blood of all engines; and a turbo charger is no
exception. Turbos operate under severe conditions, high RPMs and
extreme temperatures. Turbo bearings are damaged by oil
contamination and lack of oil.
When an engine is started, the engine exhaust causes turbine
rotation before oil pressure and flow are achieved. This results
in a few seconds of unlubricated opperation which causes metel
to metal wear in the turbo bearing (Fig. 4).
When an engine is shut down, the oil flow completely ceases.
Heat accumulates in the bearing which results in
"coking" (burnt oil). small carbon granules begin to
form which are almost as hard as industrial diamond dust (Fig.
5). This mixes with the engine's principle oil supply, slowly
contaminating it, resulting in the destruction of the engine's
lubrication protection. The ESP-Turbo Plus system eliminates these main
causes of turbo failure by automatically pre-lubricating and
post-lubricating the turbo bearings (Fig. 6).
(Fig. 4) |
Start-Up - Engine exhaust reaches the turbo
causing it to spin at 5,000 RPM or higher before the
oil reaches the bearing.
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(Fig. 5) |
Shut-Down - During a hot shut-down, oil flow
ceases during critical turbo spin-down and bearing
temperatures can reach as high as 600° F. Heat in
the turbo housing migrates to the bearing. The residual
oil is cooked into "coke" and the bearing
surface becomes damaged by the abrasive granules.
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(Fig. 6) |
With ESP-Turbo Plus - Oil flow is achieved
before start-up automatically. Metal to metal contact is
eliminated. At shut-down the ESP-luber pumps oil to
the bearing for up to 6 minutes, lubricating the bearing
during spin-down and cooling the bearing to non-harmful
temperatures. Abrasive "coke" is
completely avoided.
(See chart below) |
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