Testing 1 Manifold Coating: Apply ceramic coating on exhaust manifold and turbo housing.
Test Machine: Hitachi EX3500-2 Hydraulic Excavator
Test Engines: Cummins K-T38 C 900, 900HP @ 1800 RPM
Engine Load Factor: 85%+
Test Instrument: Testo 177-T4 Temperature Data Logger. (German)
Test Probes: Stainless Shrouded 4 metre Thermocouples.
Test Conditions: (Uncoated Engine)
Excavator was stopped for daily fuelling. Test instrument was attached to the bulkhead of the L/H engine room. Test probe was clamped to the No. 1 and 2 exhaust manifold of the L/H (non ceramic coated) engine. Instrument was set to take a temperature reading every 1 minute for a 24 hour period.
Operating Hours of Excavator during test: 23 Hours.
Test Conditions: (Ceramic Coated Engine)
Excavator was stopped again for daily fuelling. Data from test instrument was downloaded to laptop. Test probe was remove from L/H uncoated engine and clamped to No. 1 and 2 exhaust manifold of the ceramic coated R/H engine.
Operating Hours of Excavator during test: 23.4 Hours
Note * Same test probe used for uniformity of test.
Test instrument was again programmed to take a temperature reading every 1 minute for a 24 hour period. Following the ceramic engine test the excavator was again stopped for fuelling and the test instrument removed and the data download to laptop.
Test Results: Uncoated Engine
Number of Readings: 1388
Max Temperature Recorded: 346.2 C
Min Temperature Recorded: 68.5C
Average Temperature Recorded: 263.1C
Number of Readings Above 207 C: (Ignition Point of Hydraulic Oil): 1193
Average Percentage of Readings Above 207 C: (Ignition Point of Hydraulic Oil): 85%
Average Percentage of Readings Below 207 C: (Ignition Point of Hydraulic Oil): 15%
Test Result: Ceramic Coated Engine
Number of Readings: 1388
Max Temperature Recorded: 211.7 C
Min Temperature Recorded: 47.4 C
Average Temperature Recorded: 94.0 C
Number of Readings Above 207 C: (Ignition Point of Hydraulic Oil): 2
Average Percentage of Readings Above 207 C: (Ignition Point of Hydraulic Oil): .001% (Note 2 readings out of 1388 were above 207 C. One 207.1 C)
Average Percentage of Readings Below 207 C: (Ignition Point of Hydraulic Oil): 99.99%
Percentage of Temperature Reduction Ceramic Coated Manifolds versus Uncoated Manifolds: Max Temp: 39%
Percentage of Temperature Reduction Ceramic Coated Manifolds versus Uncoated Manifolds: Min Temp: 31%
Percentage of Temperature Reduction Ceramic Coated Manifold versus Uncoated Manifolds: Average Temp: 64%
The problem comes from ruptured hydraulic lines. The resulting fire can destroy the equipment. Equipment valued at 12 million dollars has been lost in this way. This is not just a mining related problem, but one that exists wherever hydraulic lines coexist with hot exhaust manifold.
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Testing 2 Manifold Coating: Apply ceramic coating on exhaust manifold and turbo housing.
Test Machine: 12L Volvo Heavy Truck Diesel Engine
Monitoring the fuel consumption of a 12L diesel transport truck engine for 15,000 mi each before and after applying ceramic coating shows an average 10.3% increase in fuel economy over a wide range of load weights. The improvement is statistically significant at the 99.9% confidence level.
HP - Torque
Chassis dynometer testing show a 7% increase in the peak rear wheel (RW) hp and the RW torque in the cruise rpm range (see graph).
The owner/operator commented that on climbs through mountains he could use a gear 1 to 1/2 higher after coating and could go higher up the mountain before needing to down shift. Also the pulling of the heaviest loads is better than expected (noticeably easier) after the coating.
Manifold Surface Temperature
The coated manifold and turbo housing surface temperature averages 232 degree C (450F) lower. The coated surfaces are below the ignition temperature of hydraulic fluid, 207 degree C (405F), reducing the risk of fire if a hydraulic leak occurs.
Underhood temperature will also be reduced significantly which will increasse the life of heat sensitive components.
Higher exhaust gas temperature burn off more particulates, thereby reducing emissions pollution.
For more info. please do not hesitate to call / WhatsApp us at 6012-9077679 or email to jason@ceramicocoating.com
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